oxygen analyser - dg instruments pty ltd 2007 1632 oxygen transmitter 7 specifications inputs •...

Oxygen Analyser

Model 1632

August 2007

August 2007

2 1632 Oxygen Transmitter

August 2007

1632 Oxygen Transmitter 3

CONTENTS

1. SPECIFICATIONS

2. DESCRIPTION

3. INSTALLATION & COMMISSIONING

4. OPERATORS FUNCTIONS - ALARMS

5. SETTING UP THE TRANSMITTER

6. MAINTENANCE

APPENDICES

1. CONSTITUENT VALUES FOR VARIOUS FUELS

2. PROBE OR SENSOR EMF TABLES

3. LOG OXYGEN SCALE

4. SAMPLE LOG PRINT OUT

5. CIRCUIT SCHEMATIC

6. MODBUS™ REGISTER MAP

DECLARATION OF CONFORMITY (LAST PAGE)

Note: This manual includes software modifications up to Version 2.31, 14

th August 2007

© Copyright NOVATECH CONTROLS PTY. LTD. - 1996 - 2006

This manual is part of the product sold by Novatech Controls Pty. Ltd. ("Novatech Controls") and is provided to the

customer subject to Novatech Controls' conditions of sale, a copy of which is set out herein. Novatech Controls' liability

for the product including the contents of this manual is as set out in the conditions of sale.

All maintenance and service of the product should be carried out by Novatech Controls' authorised dealers.

This manual is intended only to assist the reader in the use of the products. This manual is provided in good faith but

Novatech Controls does not warrant or represent that the contents of this manual are correct or accurate. It is the

responsibility of the owner of the product to ensure users take care in familiarising themselves in the use, operation and

performance of the product.

The product, including this manual and products for use with it, are subject to continuous developments and

improvement by Novatech Controls. All information of a technical nature and particulars of the product and its use

(including the information in this manual) may be changed by Novatech Controls at any time without notice and without

incurring any obligation. A list of details of any amendments or revisions to this manual can be obtained upon request

from Novatech Controls. Novatech Controls welcome comments and suggestions relating to the product including this

manual.

Neither the whole nor any part of the information contained in, or the product described in, this manual may be adapted

or reproduced in any material form except with the prior written approval of Novatech Controls Pty. Ltd.

All correspondence should be addressed to:

Technical Enquires

Novatech Controls (Aust.) Pty Ltd

309 Reserve Road

Cheltenham Victoria 3192 Phone: Melbourne +61 3 9585 2833

Australia Fax: Melbourne +61 3 9585 2844

Website: www.novatech.com.au

August 2007


USING THIS MANUAL

The Novatech 1632 Oxygen Transmitter has a variety of user-selectable functions.

They are simple to use because each selection is menu driven. For options you are not sure about; read the manual on

that particular item.

Please read the safety information below and the ‘Installation’ section before connecting power to the transmitter.

CAUTION 1 The probe or sensor heater is supplied with mains voltage. This supply has electrical shock danger to maintenance

personnel. Always isolate the transmitter before working with the probe or sensor, gas solenoids, or the transmitter.

The EARTH wire (green) from a heated probe or sensor must ALWAYS be connected to earth.

CAUTION 2 Combustion or atmosphere control systems can be dangerous. Burners must be mechanically set up so that in the worst

case of equipment failure, the system cannot generate explosive atmospheres. This danger is normally avoided with flue

gas trim systems by adjustment so that in the case of failure the appliance will not generate CO in excess of 400 ppm in

the flue. The CO level in the flue should be measured with a separate CO instrument, normally an infrared or cell type.

CAUTION 3

The oxygen sensor which is heated to over 700°C (1300°F) and is a source of ignition. Since raw fuel leaks can occur

during burner shutdown, the transmitter has an interlocking relay that removes power from the probe or sensor heater

when the main fuel shut-off valve power is off. If this configuration does not suit or if it is possible for raw fuel to come

into contact with a hot oxygen probe or sensor then the Model 1632 transmitter with a heated probe or sensor will not be

safe in your application.

An unheated probe can be utilised in such applications, however the oxygen readings are valid only above 650°C

(1200°F).

CAUTION 4 The reducing oxygen signal from the transmitter and the associated alarm relay can be used as an explosive warning or

trip. This measurement assumes complete combustion. If incomplete combustion is possible then this signal will read

less reducing and should not be used as an alarm or trip. A true excess combustibles transmitter, normally incorporating

a catalyst or thermal conductivity bridge, would be more appropriate where incomplete combustion is possible.

Also read the probe or sensor electrical shock caution in Section 2.5 and the probe or sensor heater interlock caution in

Section 3.6.

CAUTION 5 If an external pressure transducer is used to feed the process pressure to the transmitter for pressure compensation, it is

essential that the pressure transducer is accurate and reliable. An incorrect reading of pressure will result in an incorrect

reading of oxygen. It is therefore possible that an explosive level of fuel could be calculated in the transmitter as a safe

mixture.

CAUTION 6 FIL-3 filter. If the optional FIL-3 has been fitted to the 1231 probe in this installation, please read the Important Notice

in section 1.2.

August 2007


SPECIFICATIONS

1

1.1 MODEL 1632 OXYGEN TRANSMITTER FOR TWO OXYGEN PROBES

1.2 SERIES 1230 OXYGEN PROBES AND SENSORS

1.3 PURGE & CALIBRATION CHECK ACCESSORIES

1.4 FILTER PURGE SWITCH

August 2007


1.1 MODEL 1632 OXYGEN TRANSMITTER FOR TWO OXYGEN PROBES

DESCRIPTION The Novatech model 1632 oxygen transmitter provides in-situ measurement for two oxygen probes in furnaces, kilns

and boilers and flue gases with temperatures from ambient up to 1400°C (2550°F). The transmitter provides local

indication of oxygen plus thirteen other selectable variables.

One or two probes or sensors in one process can be controlled from one transmitter providing an average and/or

individual sensor signals. Two linearised and isolated 4 to 20 mA output signals are provided. Alarms are displayed at

the transmitter and relay contacts activate remote alarm devices. The transmitter, which is available for heated or

unheated zirconia oxygen probes, provides automatic on-line gas calibration check of the probe and filter purging. The

electronics self-calibrates all inputs every minute.

The 1632 has a keyboard for selecting the output range, thermocouple type, etc., as well as maintenance and

commissioning functions. The instrument is microprocessor based and all adjustments are made using the keyboard.

• Used for air / fuel ratio combustion control to provide fuel savings

• Used for product quality control in ceramic and metal processing industries

• Simple to install

• Linear output of % oxygen for recording or control

• Built in safety features

• 26 different alarm conditions that warn the operator of combustion, probe, or transmitter problems

• Isolated RS 232-C printer/computer interface and an RS 485 MODBUS network interface

• Safety interlock relay for heated probes

Oxygen Probe and Transmitter System

REF

1632 Oxygen

Transmitter

Computer and / or

Printer (Optional)

Reference Air

Purge Air

Flowmeter

Calibration

Checking Gas Calibration

Solenoid

Purge Solenoid

Zirconia Oxygen

Probe

Recorder / Controller

Alarms

Cable

August 2007


SPECIFICATIONS

Inputs

• Zirconia oxygen probe, heated or unheated

• Furnace, kiln or flue thermocouple, field selectable as type K or R.

• Main flame established safety interlock (for heated probes only)

• Purge pressure switch

• Dual Fuel selector

• Remote alarm accept

Outputs

• Two linearised 4 to 20 mA DC outputs, max. load 1000Ω

• Common alarm relay

• Three other alarm relays with selectable functions

Computer

• RS 232-C or RS 485 for connection of a computer terminal or printer for diagnostics of the transmitter, probe, sensor

or combustion process. This connection is suitable for network connection to computers, DCSs or PLCs using

MODBUS protocol.

Range of Output 1

Field selectable from the following:

Output Selection Range

Linear, Probe 1 0 to 1% oxygen to 0 to 100 % oxygen

Linear, Probe 1 and 2 averaged 0 to 1% oxygen to 0 to 100 % oxygen

(If 2 probes are used)

Log 0.1 to 20 % oxygen, fixed

Reducing 100 % to 10-4 oxygen, fixed

Reducing 10-1 to 10-25 % oxygen, fixed

Linear, probe 1, very low range 0 to 0.001% to 0 to 2.0 % oxygen (10ppm to 20,000ppm)

Range of Output 2

Field selectable from the following:

Output Zero Range Span Range

Sensor EMF 0 to 1100 mV in 100 mV steps 1000 to 1300 mV in 100

mV steps

Carbon Dioxide 0 to 10 % 2 to 20 %

Oxygen Deficiency 0 to 20% O2 deficiency 0 to 100% O2 excess

Aux Temperature 0 to 100°C (32 to 210°F) in 1 degree steps 100 to 1400°C (210 to

2550°F) in 100 degree

steps

Log Oxygen 0.1% O2 Fixed 20% O2 Fixed

Reducing Oxygen 10+2 (100%) to 10-10 % oxygen in one 10-3 to 10-30 % oxygen in

decade steps, non-overlapping one decade steps. Min

span two decades.

Linear Oxygen, probe 2 0% oxygen, fixed 1 to 100%

Combustibles %, Probe 1 0% combustibles fixed 0.5 to 2.0 %

Linear, Probe 1 and 2 averaged 0% oxygen, fixed 1 to 100%

(If 2 probes are used)

Range of Indication, Upper Line

• Auto ranging from 10-30 to 100% 02

Indication Choice, Lower Line

Any or all of the following can be selected for lower line display:

• Date - time

• Run Hours since last service

• Date of last service

• Probe 1 oxygen

August 2007


• Probe 2 oxygen

• Probe 1 EMF

• Probe 2 EMF

• Probe 1 Temperature

• Auxiliary Temperature

• Probe 2 Temperature

• Probe 1 Impedance

• Probe 2 Impedance

• Ambient Temperature

• Ambient Relative Humidity

• Carbon Dioxide

• Combustibles

• Oxygen Deficiency

The oxygen deficiency output can be used in the same way as a combustibles transmitter to signal the extent of reducing

conditions of combustion processes.

Accuracy

• ±1% of actual measured oxygen value with a repeatability of ±0.5% of measured value.

Relay Contacts

• 0.5A 24 VAC, 1A 36 VDC

Environmental Rating

• Operating Temperature: -25 to 55°C (-15 to 130°F)

• Relative Humidity: 5 to 95% (non-condensing)

• Vibration: 10 to 150Hz (2g peak)

Power Requirements

• 240 or 110V, 50/60 Hz, 105 VA (heated probe)

• 240 or 110V, 50/60 Hz, 5 VA (unheated probe)

Weight

• Transmitter, 3.75 kg (10 lbs.)

Dimensions

• 280mm (11”) W x 180mm (7”) H x 95mm (3.75”) D

Degree of Protection

• IP65 without reference air pump

• IP54 with reference air pump

Mounting

• Suitable for wall or surface mounting.

August 2007


1.2 SERIES 1230 OXYGEN PROBES & SENSORS

DESCRIPTION Novatech series 1230 oxygen probes and sensors employ state-of-the-art zirconia sensors and advanced materials, which

provide the following benefits:

• Improved control due to fast response time to typically less than four seconds

• Cost-efficient design provides improved reliability

• Longer-life probes with greater resistance to corrosion from sulphur and zinc contaminants in flue gas

• Low cost allows maintenance by replacement

• Reduced probe breakage due to greater resistance to thermal shock and mechanical damage during installation and

start-up

Series 1230 probe or sensors are simple to install and maintain. All models provide direct measurement of oxygen level.

On-line automatic calibration check is available if required. Probes or sensors may be used with Novatech oxygen

transmitters and some model transmitters from other manufacturers. See Set-up 5.5.90 for more details.

All Novatech oxygen probe or sensors are designed and manufactured to exacting standards of performance and

reliability. Series 1230 probe or sensors are the result of extensive research and development by Novatech, industry and

government agencies. Novatech Controls provides application and after sales support for oxygen probes, sensors and

transmitters, worldwide.

Model 1231 Heated Oxygen Probe

Model 1232 Unheated Oxygen Probe

REF

August 2007


Model 1234 Oxygen Sensor

STANDARD PROBE ‘U’ LENGTHS

1231 1232 250 mm (10”) 500 mm (20”)

350 mm (14”) 750 mm (30”)

500 mm (20”) 1000 mm (40”)

750 mm (30”) 1500 mm (60”)

1000 mm (40”)

1500 mm (60”)

2000 mm (80”)

Ordering Information

1. Probe insertion length (from process end of mounting thread to probe sensing tip).

2. Mounting thread (process connection), BSP or NPT (for size of thread refer to specifications).

3. Lagging extension length, if required.

4. If model 1232 probe, state preferred thermocouple type (refer to specifications).

EXHAUST

1234 OXYGEN

SENSOR

NOVATECH

CONTROLS

CABLE GLAND

ID LABEL

EXHAUST 1/4" NPT FEMALE

GAS INLET 1/4" TUBE ELBOW

August 2007


Important Notice Regarding

1231 Probe Option - FIL-3

WARNING: The only identifiable standard for flame arresters for general use is British Standard BS EN 12874:2001.

British Standard BS EN 12874:2001 refers to an operating environment up to 150 Degrees Centigrade.

The FIL-3 device optionally fitted to 1231 Heated Zirconia Probes (the “Probes" or "Probe") operate in an environment

considerably greater than 150 Degrees Centigrade.

Therefore, we know of no Australian, British, European or USA standard applicable to flame arresters or their testing

above 150 degrees Centigrade. Consequently, the FIL-3 device cannot be certified as a safety device.

The probe is only one of several potential sources of ignition. Extreme care is required when using the probes during

the start up processes of a combustion appliance.

The Novatech Burner Interlock Relay facility, which is a standard part of the Novatech transmitter, is designed to be

wired to the main safety shut-off fuel valves in a way that can shutdown the probe heater when the fuel valves are

closed.

The risk of ignition of flammable gas mixture at the hot end of the Probe can only be minimised by correct use,

maintenance and operation of the FIL-3 device. The user of the FIL-3 device is responsible for verification and

maintenance and correct use and operation of the FIL-3 device.

THE USER AGREES THAT IT USES THE PROBE AND THE FIL-3 DEVICE AT ITS SOLE RISK. NOVATECH

CONTROLS PTY LTD, TO THE FULL EXTENT PERMITTED BY LAW, GIVES NO WARRANTIES OR

ASSURANCES AND EXCLUDES ALL LIABILITY (INCLUDING LIABILITY FOR NEGLIGENCE) IN

RELATION TO THE PROBE AND THE FIL-3 DEVICE.

The user must ensure that it correctly follows all instructions in relation to the Probe and FIL-3 device, correctly

understands the specifications of the Probe and FIL-3 device and ensures that the Probe and FIL-3 device are regularly

inspected and maintained.

FIL-3 equipped Probes should be inspected at least once a year for corrosion and more frequently if there is any reason

to suspect that corrosion may have occurred.

August 2007


OXYGEN PROBE SPECIFICATIONS

MODEL 1231 1232

Application Combustion flue Combustion flue gases

gases below above 700°C (1290°F) with

900°C (1650°F) no contaminants.

Refer to note 1 eg. natural gas, light oils

Temperature Range 0 to 900°C. Refer to note 2 700 to 1400°C

(32 to 1650°F) (1470 to 2550°F)

Length 250 to 2000 mm 500 to 1500 mm

(10” to 80”) (20” to 60”)

Process 1 ½" BSP ¾" BSP

Connection or NPT or NPT

Electrical Weatherproof plug-in connector or optional screw terminals. The plug connector can be

Connection supplied with the cable.

Cable Order a specific length with the transmitter

Heater Yes No

Thermocouple K, integral R, integral

Response Time Typically < 4 secs. Typically < 1 sec

Head Temperature -25 to 100°C (-15 to 210°F) with weatherproof connector

-25 to 150°C (-15 to 300°F) with screw terminals

Reference Gas Ambient air 50 to 150 cc/min (3 to 9 scim). Pump can be supplied with transmitter

Ref Air Connection 1/4" NPT Integral air line in probe cable. Barbed fitting to

3/16" ID PVC tube.

Filter Removable sintered titanium alloy particulate filter,

30 micron standard, optional 15 micron available. Refer to note 2

Calibration Check Gas 1/8" NPT female 1/8" NPT female

Connection

Weight 2 kg (4.4 lb) plus 1 kg (2.2 lb) plus

165 g (5.8 oz) / 100 mm 100 g (3.5 oz) / 100 mm

(4”) length (4”) length

Notes:

1. Care must be taken to avoid contact with explosive or inflammable gases with 1231 heated probes and 1234

oxygen sensors when hot. Novatech transmitters have built in safety protection.

2. Process gas temperature must be below 800°C if the filters are fitted.

Please contact factory for corrosives other than sulphur or zinc. We can provide test materials to try in your atmosphere.

August 2007


OXYGEN PROBE MODEL SELECTION GUIDE

Heated probes-temperature range 0-900°C (1650°F).

1231 - U Length - Outer - Internal - Mounting

Sheath Thermocouple Thread

Basic model 2. 250mm (10”) 1. 316 SS max 850°C 1. Type K max 900°C 1. 1 ½ BSP

3. 500mm (20”) (1560°F) (1650°F) 2. 1 ½ NPT

4. 750mm (30”) 2. Inconel *(1)

5. 1000mm (40”)

6. 1500mm (60”)

7. 2000mm (80”)

*Note: (1) The Inconel option has all inconel wetted parts except for the ceramic sensor and viton ‘o’ rings.

Unheated probes for clean gases-temperature range 700-1400°C (1290-2550°F).

1232 - U Length - Outer Sheath - Internal Thermocouple - Mounting Thread

Basic model 3. 500mm (20”) 1. 253 MA-max 1000°C 1. Nil *(2) 1. 3/4” BSP fixed

4. 750mm (30”) (1830°F) 4. Type R max 1400°C 2. 3/4” NPT fixed

5. 1000mm (40”) (2550°F)

6. 1500mm (60”) 3. High Purity Alumina

max 1300°C (2370°F) Horizontal

max 1400°C (2550°F) Vertical

4. 446 SS max 1000°C (1830°F)

*Note: (2) A standard oxygen probe for carburising furnaces, has a 253 MA sheath.

1234 SENSOR SPECIFICATIONS

Range of measurement: 1 ppm to 100% oxygen

Output: EMF = 2.154.10-2

.T.loge (0.209/oxygen level of the sample)

Accuracy: ± 1%

Thermocouple: Type K

Heater: 110 VAC 50 / 60Hz, 100 watts

Heater proportional band: 80°C (175°F)

Speed of Response: Less than 100 milliseconds

Sample flow rate: 1 to 5 litres / minute (120 to 600 scfm)

Differential Pressure: 80 to 800 mm (3 to 30”) WG gives a flow of 1 to 5 litres / min (120 to 600 scfm)

Process Connections: 1/4” NPT female, inlet and outlet

Dimensions: 300 mm (11.81”) high by 125 mm (4.92”) wide by 88 mm (3.46”) deep

Weight: 2.1 kg (4.6 lb)

August 2007


1.3 PURGE & CALIBRATION CHECK ACCESSORIES Due to the absolute measurement characteristics of zirconia sensors and the self-calibration features of Novatech

transmitters, probe calibration checks with calibrated gas are not normally required. In some installations however,

automatic gas calibration checks are required by Environmental Protection Authorities and by engineering management

in Power Stations, Oil Refineries and similar large end users.

Novatech probes and transmitters provide a ready method of connecting on-line calibration check gases. They provide

on-line automatic checking of probe and transmitter calibration, as well as a probe purge facility.

The absolute characteristics of zirconia sensors require only one calibration check gas to properly check the probe’s

performance. Where required however, the dual gas calibration check facility can be utilised.

Dirty flue gas applications often require the back purge facility to keep a probe filter free from blockage. (In these

applications, it is more reliable to install probes pointing vertically downwards with no filter). Purge and calibration

check solenoid valves can be operated manually or automatically from a 1632 transmitter.

The external components required for automatic / manual gas calibration checking are:

• A calibration check gas flow meter/regulator

• A mains voltage (240 or 110 VAC) solenoid valve for each calibration check gas

The external components required for automatic / manual purging are:

• A mains voltage (240 or 110 VAC) purge solenoid valve

• A purge pressure switch, 0 to 35 kPa (0 to 5 psi), to test for filter blockage.

The user should supply:

• Span gas cylinder(s), typically 2 % oxygen in nitrogen or a similar percentage of 02 close to the normal level in the

gas stream being measured, to ensure fast recovery.

• A 100 kPa (15 psi) clean and dry instrument air supply when filter purging is required.

1.4 FILTER PURGE PRESSURE SWITCH To automatically sense a blocked probe filter, a pressure sensor should be connected to the ‘purge’ line to the probe

‘cal’ port. It should be adjusted so that it energises just above the purge pressure with a new or clean filter installed.

The switch contacts should be connected to terminals 12 & 13 (PURGE FL SWITCH).

If the filter is still blocked or partly blocked after an auto purge cycle, the pressure switch will energise and cause a

‘Probe Filter Blocked’ alarm. The contacts must be normally closed.

The pressure switch should have an adjustable range of 0 to 100 kPa (0 to 15 psi).

August 2007


DESCRIPTION

2

SECTION

NUMBER

2.1 THE ZIRCONIA SENSOR

2.2 THE OXYGEN PROBE OR SENSOR

2.3 THE TRANSMITTER

2.4 ALARMS

2.5 HEATER

2.6 APPLICATIONS WHERE SENSING POINT

IS NOT AT ATMOSPHERIC PRESSURE

2.7 SENSOR IMPEDANCE

2.8 AUTO CALIBRATION—ELECTRONICS

2.9 MANUAL CALIBRATION—PROBES

2.10 AUTO CALIBRATION CHECKING—PROBES

2.11 AUTO PURGE

2.12 RS 485 NETWORK (MODBUS™) AND 232-C PORT

2.13 AUXILIARY TEMPERATURE THERMOCOUPLE

2.14 WATCHDOG TIMER

2.15 BACK UP BATTERY

August 2007


DESCRIPTION

2.1 THE ZIRCONIA SENSOR The transmitter input is provided for a solid electrolyte oxygen probe, which contains a zirconia element and

thermocouple. The probe is designed to be inserted into a boiler or furnace exit gas flue or similar process. A 1234

sensor is designed to be installed outside of the flue or process. Sampling lines and filters are not required for in-situ

probes but they are required for 1234 sensors. When a sampling line is required, the sample flows to the sensor under

process pressure in most applications. In applications where the process pressure is negative or neutral, a suction pump

will be required. A reference air pump is provided in the 1632 oxygen transmitter. The internal construction of a probe

or sensor is shown as follows.

Internal electrode wire

Zirconia Disc

Thermocouple

Wires

Electrode Material

(required only

Heater

with heated

probes)

External Wire

Contact

Thermocouple

Junction

Internal Electrode

Four-Bore Thermocouple

Insulating Tubing

Alumina Tube

Schematic View of a Zirconia Sensor Assembly

The heater control in the 1632 transmitters consists of a time proportioning temperature controller and solid state relay

so that the thermocouple junction is controlled to over 700°C (1300°F). Probes operating in a combustion environment

above 650°C (1200°F) do not require a heater. When exposed to different oxygen partial pressures at the outside and

inside of the sensor, an EMF (E) is developed which obeys the Nernst equation:

E (millivolts) = RT

4F loge

(PO2) INSIDE

(PO2) OUTSIDE

Where T is the temperature (K) at the disc (>650°C (1200°F)), R is the gas constant, F is the Faraday constant and (PO2)

INSIDE and (PO2 ) OUTSIDE are the oxygen partial pressures at the inner and outer electrodes, respectively, with the

higher oxygen partial pressure electrode being positive.

If dry air at atmospheric pressure, (21 % oxygen) is used as a reference gas at the inner electrode, the following

equations are obtained:

E (millivolts) = 2.154 x 10-2 T loge 0.21

(PO2) OUTSIDE

Transposing this equation

(%O2) OUTSIDE (ATM) = 0.21 EXP -46.421E

T

The 1632 transmitter solves this equation which is valid above 650°C (1200°F). The probe heater, or the process

maintains the sensor temperature at this level.

2.2 THE OXYGEN PROBE OR SENSOR The probe assembly provides a means of exposing the zirconia sensor to the atmosphere to be measured with sensor,

thermocouple and heater wires connected via the transmitter lead. Reference air is fed via the plug for unheated probes

and via a separate gas thread connection for heated probes.

Connections are provided on probes for an in-situ gas calibration check. A cleaning purge of air can be admitted via the

calibration gas check entry. The outer sheath of probes can be metal or ceramic, depending on the application.

August 2007


Calibration check can be achieved on 1234 sensors using a three way solenoid which blocks the sample and at the same

time admits a calibration check gas to the sensor. Purging a probe for any dust build up can be achieved in the same

way.

In-situ zirconia oxygen probes will give a lower oxygen reading than a sampled gas measurement on a chromatograph or

paramagnetic transmitter because the flue gas contains a significant level of water vapour and a sampling system

removes the water vapour through condensation. The oxygen content then appears as a higher percentage of the

remaining gas. For example: If the gas contained five parts oxygen and fifteen parts moisture, removing the moisture

would leave the oxygen at 5.88%. This phenomena will depend on the fuel and the completeness of combustion. They

are common to all in-situ oxygen sensors.

2.3 THE TRANSMITTER The top line of the transmitter display will read oxygen in either % or ppm.

The 1632 transmitter is a transmitter with two 4 to 20 mA outputs. One output is linear oxygen with selectable span.

The second output can be selected as oxygen deficiency, combustibles, auxiliary temperature, reducing oxygen, percent

carbon dioxide, sensor EMF or a logarithmic oxygen range. Four alarm relays are provided. Refer to the sections 4.2

and 4.3 for more details.

The 1632 transmitter is designed to operate with either one or two heated or unheated, zirconia probes or sensors in one

process. If two sensors are being used, the transmitter can average the two oxygen signals, alarm when there is a high

difference, transmit and display the average and/or individual oxygen signals.

If heated probes are being used, the transmitter will maintain the temperature of the sensor(s) to over 700°C (1300°F).

If the flue gas temperature is above 850°C (1560°F), the probe heater will cut out completely and the process will

provide probe heating. The transmitter solves the Nernst equation and will provide accurate oxygen measurements up to

1500°C (2730°F), although most probes are suitable only to 1400°C (2250°F). 1231 heated probes are limited to 900°C

(1650°F).

2.4 ALARMS Refer to OPERATOR FUNCTIONS Section 4 for details on alarm functions.

2.5 HEATER

CAUTION The probe or sensor heater is supplied with mains voltage. This supply has electrical shock danger to maintenance

personnel. Always isolate the transmitter before working with the probe or sensor.

The EARTH wire (green) from the probe/sensor must always be connected to earth.

The heater is supplied from the mains power directly, and the temperature is controlled initially at over 700°C (1300°F)

after turn on.

2.6 APPLICATIONS WHERE SENSING POINT IS NOT AT ATMOSPHERIC

PRESSURE To apply the 1632 transmitter to processes that have pressure at the point of measurement significantly above or below

atmospheric pressure, then compensation must be applied. (Refer to Set-up Steps 37 and 38 in Section 5.5). If two

probes are being used, they must be close to the same pressure.

If the process pressure is not constant, it can be measured by a pressure transducer and fed into the oxygen transmitter as

a 4-20mA signal. The pressure compensation will then change the oxygen reading according to the current process

pressure.

2.7 SENSOR IMPEDANCE The zirconia sensor impedance is a basic measurement of the reliability of the oxygen reading. A probe or sensor with a

high impedance reading will eventually produce erroneous signals. The transmitter checks the zirconia sensor

impedance every 24 hours and if the impedance is above the maximum level for a specific temperature then the

impedance alarm (Sensor Fail) will be activated. Typical sensor impedance is 1 KΩ to 8 KΩ at 720°C (1320°F).

The impedance measurement can be updated manually whenever the sensor is over 700°C (1290°F) by pressing the

“AUTOCAL” button while in “RUN” mode. The “Z” will appear in the top RH corner of the display for 3 seconds to

confirm the measurement.

August 2007


2.8 AUTO CALIBRATION - ELECTRONICS The transmitter input section is self-calibrating. There are no adjustments. The analog to digital converter input stages

are checked against a precision reference source and calibrated once every three seconds. Should the input electronics

drift slightly then the drift will be automatically compensated for within the microprocessor. If the calibration factors

are found to be have been changed more than expected, an ‘ADC Warning’ alarm is generated. If a large error occurs

due to an electronic fault then an ‘ADC CAL FAIL’ alarm will occur.

A one-off calibration procedure of the precision reference sources should never need to be repeated for the instrument

life unless the instrument has been repaired. For a description of the calibration procedure, refer to ‘Setting Up The

transmitter’ Section 5.5, items 7, 8 9 and 10.

The digital to analog converters or output section of the transmitter are tested for accuracy when the ‘AUTOCAL’

button is pressed, and when the transmitter goes through the start up procedure. If the output calibration factors are

found to have changed more than expected, the ‘DAC Warning’ alarm will occur. If either output has a fault, the ‘DAC

CAL FAIL’ alarm will occur. The D/A sections are re-calibrated by pressing the ‘AUTO CAL’ button on the keyboard

while in 'SET-UP' mode. Each of the output channels have three menu items which provide manual calibration (set-up

13 to 18). If manual is selected in set-up 13 or 16, the ‘AUTO CAL’ will be skipped and the manual calibration factors

will be retained. See section 5.5 set-up 13, and section 6.3 for more details.

All output signals will drop to 0 mA for one-second period. It is suggested that a D/A re-calibration be performed after

the instrument has stabilised, approximately 30 minutes after first switching on and after Setting Up The transmitter

Section 5.5, items 6, 7, 8 and 9 have been completed, and then annually.

2.9 MANUAL CALIBRATION - PROBES Calibration of the probe generally only requires the Sensor Offset to be set. See Section 5.5.11 for more details.

If the offset for a sensor is not set the error will generally be less than 5% of the actual oxygen reading. By setting the

offset the error will be less than 1% of the oxygen actual reading.

If a probe made by a manufacturer other than Novatech Controls is used on the Novatech transmitter, and/or improved

accuracy is required at process levels of oxygen (well away from 20.9%) the “Low Oxygen Calibration” trim factors can

be entered. (See also Section 5.5.90)

To manually set the “Low Oxygen Calibration” first set the Sensor Offset, then the “Low Oxygen Calibration”.

1. To check a probe offset on site, the probe must be sensing air, with reference air, and allowed to settle at the probe

operating temperature for 30 minutes. Read the offset in ‘RUN’ mode in millivolts on the lower line. Offset errors can

occur if the sensor does not have some air passing over it. A gentle flow (<0.5 l/min) of air in the calibration check port

can be provided by a reference air pump or similar.

The best results will be obtained if the probe is removed from the process.

For heated probes, if the combustion appliance is not operational and the probe heater is interlocked with the ‘BURNER

ON’ signal, the ‘BURNER BYPASS’ switch should be set to ‘ON to power the probe heater after removing the probe

from the flue.

CAUTION DANGER

Return the ‘BURNER BYPASS’ switch to normal (off) before installing the probe in the flue.

For unheated probes, the probe sensing tip must be raised to at least 650°C (1200°F) with a portable furnace.

Determine the probe offset in ‘RUN’ mode. Select ‘Sensor EMF’ on the lower line. With probe in air, stabilised at

temperature for 30 minutes, read the ‘Sensor EMF’. Switch back to ‘set-up’ mode and enter ‘Sensor Offset’ of equal

value and the same polarity.

eg. If the measured ’SENSOR OFFSET’ was -1.2 mV, enter -1.2 mV.

When reading the EMF offset, the flue pressure compensation must be set. If the probe has been removed from the flue,

set the flue pressure compensation set up to “Fixed” in set-up 34, and the value to 0 in set-up step 38.

2. To set the probe “Low Oxygen Calibration”, replace the air purge in the calibration check port with a flow of gas

from a certified gas bottle. A flow of <1 l/min should be used. After purging for 1 minute compare the oxygen reading

to the oxygen concentration on the bottle certificate. If the transmitter is reading lower than the certified level, switch to

August 2007


the ‘set-up’ mode and raise the figure set-up 90 (for sensor 1). An increase of 1% in the set-up entry will increase the

oxygen reading by about 3% of the actual oxygen reading.

NOTE: If the set-up items 90 and 91 are not available, see section 5.1.

It is very unusual to need to change the settings by more than 1%. If a setting of more than 1% seems

necessary, check for gas leaks, reference air flow or excess calibration gas flow.

2.10 AUTO CALIBRATION CHECKING - PROBES On-line automatic gas calibration check is not normally required. Where it is required however, the probe can be

checked for accuracy in-situ and on-line. Solenoid valves can admit up to two calibrated gas mixtures into the probe via

solenoid valves under microprocessor control on a timed basis. For details on installation refer Section 3.11. For details

on setting up this facility refer to Set-up steps 57 to 69 in Section 5.5.

During probe auto calibration checking, the transmitter output will freeze and remain frozen for a further adjustable

period, allowing the probe time to recover and continue reading the flue gas oxygen level.

Calibration check gases may be manually admitted by pressing the ‘CAL’ buttons on the keyboard while in ‘RUN’

mode. The transmitter output is frozen during the pressing of these buttons and immediately becomes active when the

button is released. If calibration gas checking is enabled in the Set-up menu for either gas, an automatic gas cycle can

be started by pressing the ‘CAL’ buttons in RUN mode. Pressing any other button can terminate the cycle.

2.11 AUTO PURGE In oil and coal fired plants, it is possible for the probe sensing filter to become blocked. An automatic purge cycle can

be set up so that a blast of air, maximum 100 kPa (14.5 psi), will automatically back-flush the probe filter on a timed

basis. Refer to Set-up steps 52 to 56 in Section 5.5. A purge pressure switch will sense if there is insufficient flow to

clear the filter during the purge cycle. In this case a ‘PROBE FILTER’ alarm will occur. The probe can be manually

purged from the keyboard while in ‘RUN’ mode. The transmitter output is not frozen during or after the pressing of this

button.

If two probes are being used, the two probes could be driven by a common solenoid but separate pressure regulators and

pressure switches (See section 3.11)

2.12 RS 485 NETWORK (MODBUS) AND RS 232C PORT The serial port has two functions. -

It can be configured to connect up to 31 transmitters together on a MODBUS™ RS485 network.

Each individual transmitter can be interrogated by a computer or PLC. The values of oxygen, sensor EMF, sensor

temperature, sensor impedance for both oxygen sensors (if two sensors are being used on one transmitter) can be read

over the network. The alarms status can also be checked over the network.

For the connection details, see Section 3.15 and Appendix 6.

It can be used to log the transmitter readings by connecting the transmitter to a printer, a data logger, or any

computer using an RS232-C com port.

When it is to be used to log the transmitter readings, use set-up step 82 to selected the items to be sent to the data logger.

The log period may be selected in set-up step 83, and the baud rate may be set in set-up step 84. Alarms, including the

time they occurred, will be transmitted to the printer and computer whenever they are first initiated, accepted and

cleared. The protocol for the serial port is eight data bits, one stop bit, no parity.

2.13 AUXILIARY TEMPERATURE THERMOCOUPLE A flue thermocouple must be connected to the AUX thermocouple input when combustibles display is required.

The AUX thermocouple may also be used to monitor and display any process temperature.

August 2007


2.14 WATCHDOG TIMER The watchdog timer is started if the microprocessor fails to pulse it within any one-second period, (ie. fails to run its

normal program). The microprocessor will then be reset up to three times until normal operation is resumed. Reset

cycles are displayed by the POWER light on the keyboard. A steady ‘ON’ light indicates normal operation. If the

program has not resumed normal operation after three attempts to reset, the common alarm relay will be activated. The

reset function will continue repeatedly after the alarm. If a successful reset is achieved, the alarm will be cancelled and

the transmitter will continue to run normally.

2.15 BACK-UP BATTERY The transmitter’s RAM and real-time clock are backed up by a lithium battery in the event of power failure. All set-up

variables are saved and the clock is kept running for approximately ten years with the power off. The battery module

should be replaced every 8 years. (It is the battery shaped device clipped in a socket labelled M1.)

August 2007


INSTALLING &

COMMISSIONING

3

SECTION

NUMBER INSTALLATION

3.1 MOUNTING THE TRANSMITTER

3.2a INSTALLING AN OXYGEN PROBE

3.2b INSTALLING A 1234 OXYGEN SENSOR

3.3 INSTALLING THE AUXILIARY THERMOCOUPLE

3.4 SHIELD CONNECTIONS

3.5 ELECTRICAL CONNECTIONS

3.6 HEATER INTERLOCK RELAYS

3.7a CONNECTING AN OXYGEN PROBE CABLE

3.7b CONNECTING A 1234 SENSOR CABLE

3.8 CONNECTING THE AUXILIARY THERMOCOUPLE (OPTIONAL)

3.9 CONNECTING THE OUTPUT CHANNELS

3.10 CONNECTING THE ALARMS

3.11 CONNECTING THE AUTOMATIC PURGE & CALIBRATION CHECK SYSTEM

3.12 CONNECTING REFERENCE AIR

3.13 CONNECTING THE DUAL FUEL INPUT

3.14 CONNECTING THE PRINTER

3.15 CONNECTING THE TRANSMITTER TO A MODBUS™ NETWORK

COMMISSIONING

3.16 CONNECTING POWER

3.17 COMMISSIONING - SET-UP MODE

3.18 COMMISSIONING - RUN MODE

3.19 BURNER BY-PASS SWITCH

3.20 CHECKING ALARMS

3.21 PROBE CALIBRATION CHECK

3.22 FILTER PURGE SET-UP PROCEDURE

3.23 CALIBRATION CHECK GAS SET-UP PROCEDURE

3.24 DUST IN THE FLUE GAS

3.25 STRATIFICATION

3.26 CONNECTING A PRESSURE TRANSDUCER

August 2007


INSTALLATION

3.1 MOUNTING THE TRANSMITTER Surface mount the transmitter case on to a flat surface or bracket, using the four mounting brackets provided.

Make sure the ambient temperature is below 50°C, and that the radiated heat from furnaces and boilers is kept to a

minimum.

Case Mounting Dimensions

3.2a INSTALLING A 1231 OXYGEN PROBE Weld a BSP or NPT socket to the flue in a suitable position for flue gas sensing. For the correct size of socket refer to

probe data in Section 1. The closer to the source of combustion the smaller will be sensing lag time, allowing better

control.

The probe has a typical response time of less than four seconds, so most of the delay time is normally the transit time of

the gas from the point of combustion to the point of sensing.

Probes can be mounted at any angle. If there are any particulates in the flue gas, a filter can be omitted by pointing the

probe vertically downwards. Otherwise the filters may have to be replaced periodically.

If installing a probe into a hot environment, slide the probe in slowly to avoid thermal shock to the internal ceramic

parts. If the flue gas is 1000°C (1830°F), it should take approximately five minutes to install a 500 mm (20”) probe,

moving it in about 50 mm (2”) steps.

Gland Plate

Vertical Mounting Brackets Horizontal Mounting Brackets

15

0m

m

280mm

180

mm

22

5m

m

250mm 325mm

11"

7"

6"

12.8" 9.8"

9"

REAR VIEW

200mm 8"

40mm 1.6"

REAR VIEW

August 2007


Oxygen Probe Mounting

CAUTION

It is important that there is no air in leakage upstream of the oxygen sensing point, otherwise there will be a high oxygen

reading.

If the probe is to be installed on a bend in the flue, it is best located on the outer circumference of the bend to avoid dead

pockets of flue gas flow. While the standard 1231 probe with a ‘U’ length of 250 mm (10”) will suit most low

temperature flue applications, it is occasionally necessary to have a longer probe with the sensing tip in the center of the

flue gas stream.

Although it is rare, occasionally a probe may sense oxygen vastly differently from the average reading in the flue gas. If

it occurs, then the probe should be moved, or a longer probe installed. This phenomena is normally caused by

stratification of the flue gas.

REF

Preferred mounting angle if

there are particulates in the

flue gas and no filter is used.

RE

F

Furnace, flue

Probe may be mounted

horizontal

August 2007


3.2b INSTALLING A 1234 OXYGEN SENSOR Mounting - Screw the 1234 sensor to a wall or similar surface with the piping connections at the bottom.

1234 Sensor Mounting Dimensions

Sample Piping - Connect the gas sample piping to the “sample in” port. If the process, boiler, kiln or furnace has a

positive pressure, no suction will be required. If the sample is under a negative pressure, connect a pump to the “inlet”

port as shown below. The flow rate should be within the range of 1 to 5 litres/minute (120 to 600 scfm).

3.3 INSTALLING THE AUXILIARY THERMOCOUPLE Weld a 1/2 inch BSP mounting socket to the flue within about 300 mm (12”), and upstream of the oxygen probe. The

thermocouple should be of similar length to the oxygen probe to prevent flue temperature distribution errors.

3.4 SHIELD CONNECTIONS All external wiring to the 1632 transmitter should be shielded. Do not connect shields at the field end. Simply clip off

and insulate. An extra terminal strip may be required to connect all shields together. This should be supplied by the

installer.

Optional vent to

atmospherre

Optional return

to flue

Upward sloping

sample line 3/8”

stainless steelFlue

Gas

Flowmeter

Sampling

Probe

1234

Sensor

Vent or return

to process

Dry

Process

Gas

1/4" Stainless Steel Tube

1234

Sensor

SAMPLE IN

EXHAUST

1234 OXYGEN SENSOR

NOVATECHCONTROLS

CABLE

LABEL

EXHAUST 1/4" NPT

FEMALE

INLET 1/4" TUBE

10

"

2.7"

25

0.0

02

5.0

01"

1.2"30

.00

56.00

0.8"

20.00

173.00

6.8"

August 2007


3.5 ELECTRICAL CONNECTIONS All wiring should comply with local electrical codes. The printed circuit boards are fully floating above earth. All earth

and shield connections should be connected to the earth stud on the LHS inside the case. Before connection of mains

power check that the 115 / 230 volt power selector switch is set to the correct voltage.

Connection Diagram for 1632 Transmitter and one or two 1231 / 1234 Heated Sensors

21 RS-232 Tx

22 Network -

23

24

25

26 Output 1-

27 Output 2+

28 Output 2-

29 Common Alarm

30 Common Alarm

31 Alarm 2

32 Alarm 2

33 Alarm 3

34 Alarm 3

35 Alarm 4

36 Alarm 4

SENSOR #1

SENSOR #2

4-20mA OutputsSelectableranges

Optional AlarmRelay ContactsNormally Closed

Mains Power

Supply240/115VAC

41

42

43 Cal 1 Sol

44 Cal 1 Sol

45 Cal 2 Sol

46 Cal 2 Sol

47 Mains E

48

49 Mains N

50 Mains A

Purge Sol

Purge Sol

51 Heater #1

52 Heater #1

White

White

White

White

53 Heater #2

54 Heater #2

Network +

Serial Common

Output 1+

Burner safety lock,or if safety interlocknot required, linkterminals 18 & 19

Orange

Brown

Black

Blue

Black

Blue

Orange

Brown

Purge Flow

SwitchPurge Flow

Remote Alarm

ResetRemote Alarm

Burner On Input

Burner On Input

RS-232 Rx

Fuel 1/2

18

19

20

15

16

17

Probe #2+

Probe #2-

Fuel 1/2

RGC I/P-

12

13

14

9

10

11

Probe TC+

Probe TC-

Probe TC2/Aux+

Probe TC2/Aux-

+12V

RGC I/P+

6

7

8

3

4

5

Probe +

Probe -

1

2

August 2007


All wiring should comply with local electrical codes. The printed circuit boards are fully floating above earth. All earth

and shield connections should be connected to the earth stud on the LHS inside the case. Before connection of mains

power check that the 115 / 230 volt power selector switch is set to the correct voltage.

Connection Diagram for 1632 Transmitter and one or two 1232 Unheated Sensors

21 RS-232 Tx

22 Network -

23

24

25

26 Output 1-

27 Output 2+

28 Output 2-

29 Common Alarm

30 Common Alarm

31 Alarm 2

32 Alarm 2

33 Alarm 3

34 Alarm 3

35 Alarm 4

36 Alarm 4

PROBE #1

PROBE #2

4-20mA OutputsSelectableranges

Optional AlarmRelay ContactsNormally Closed

Mains Power Supply240/115VAC

41

42

43 Cal 1 Sol

44 Cal 1 Sol

45 Cal 2 Sol

46 Cal 2 Sol

47 Mains E

48

49 Mains N

50 Mains A

Purge Sol

Purge Sol

51 Heater #1

52 Heater #1

53 Heater #2

54 Heater #2

Network +

Serial Common

Output 1+

Burner safety lockor if safety interlocknot required, linkterminals 18 & 19

Orange

Black

Red

Red

Orange

Black

Purge Flow Switch

Purge Flow Switch

Remote Alarm Reset

Remote Alarm Reset

Burner On Input

Burner On Input

RS-232 Rx

Fuel 1/2

18

19

20

15

16

17

Sens #2+

Sens #2-

Fuel 1/2

RGCI/P-

12

13

14

9

10

11

Probe TC+

Probe TC-

Probe TC2/Aux+

Probe TC2/Aux-

+12V

RGCI/P+

6

7

8

3

4

5

Probe +

Probe -

1

2

August 2007


3.6 HEATER INTERLOCK RELAYS

CAUTION

Explosion protection for heated probes is achieved by switching the power to the probe heater off whenever the main

fuel valve is closed.

The principle of safety is that if the main fuel valve is open then main flame has been established. With this primary

source of ignition on, the probe heater can be safely switched on. The most dangerous situation is if fuel leaks into the

combustion appliance when the fuel valve is closed. When power is removed from the main fuel valve the heater should

also be switched off.

To achieve this protection, connect a main fuel valve voltage free contact to the ‘BURNER ON SWITCH’ terminals 18

& 19. When the main fuel valve is open, the voltage free contact should be closed. For installations where there is no

risk of explosion, connect a link between terminals number 18 & 19.

Heater Supply Interlock Connection for Heated Probes

If a safety interlock is not required, a wire must be connected between terminals 18 &19 to enable –

• The heaters on heated probes

• Process alarms

• Auto-purge and auto-cal checking.

3.7a CONNECTING AN OXYGEN PROBE CABLE Connect the probe lead as shown in the following drawings. Unheated probe leads have integral reference air tube. An

adaptor has been supplied to connect this tube to quarter inch flexible PVC tubing, from the air pump or reference air

supply.

Burner on Switch

For Safety Interlock

Contact must be closed when

main fuel valve is open

18

19

August 2007


B

Orange

Black1 Probe +

2 Probe -

3 Probe TC +

4 Probe TC -

ShieldCommonTerminal

OtherShields

Green &Yellow(Shield)

SensorZirconia

Red

A

ProbeThermocouple

E

C

MainsEarth

Probe HeadConnector

Note 1: Jumper terminals 3 & 4to terminals 5 & 6 if

temperature display isrequired.Use copper wire.

efficiency or flue

*Note 1

Ref Air

Reducing Fitting

1/4" PVC tube toreference air supply.

A

B

CD

E

F

G

Plug mountedon head viewedfrom outside ofhead.

(Optional)

Earth Stud

(By Installer)

Connection of Probe Cable for Unheated Probes Models 1232.

Connection of Probe Cable for Heated Probes Model 1231.

C

B

A

F

D

E

G

Orange

Black

Brown

Blue

White

White

Mains

Earth

1 Probe

2 Probe -

3 Probe TC

4 Probe TC -

Shield

Common

Terminal

(By installer)

Green

Probe

Thermocouple

Probe

Heater

Probe

Earth

Other

Shields

Probe

Head

Green &

Yellow

(Shield)

Zirconia

Sensor

Earth

Stud

51

52

August 2007


3.7b CONNECTING A 1234 SENSOR CABLE Remove the two screws from the cable gland end of the 1234 sensor. Connect the wiring as shown below. Be sure to

connect an earth to the earth stud. Replace the end plate. Tighten the cable gland onto the cable.

Connecting a 1234 Sensor Cable

3.8 CONNECTING THE AUXILIARY THERMOCOUPLE (OPTIONAL) For 1231 heated probes, the auxiliary thermocouple must be a separate TC with the junction isolated from earth,

mounted near to and upstream of the oxygen probe. It can be either a K or R type thermocouple. It is optional. If the

auxiliary temperature is not to be displayed or transmitted, then an auxiliary TC is not necessary.

3.9 CONNECTING THE OUTPUT CHANNELS The two 4 to 20 mA DC output channels are capable of driving into a 1000Ω load.

3.10 CONNECTING THE ALARMS A common alarm, which should be connected for all installations initiates on alarms functions described below. Three

additional alarm relays are available for selectable functions as listed in Section 4.2 and 4.3. Each relay has normally

closed contacts. The contacts will open in alarm condition except for the optional horn function that operates with

normally open contacts. Relays are connected as follows:

Relay Terminal Numbers

Common Alarm 29 & 30

Alarm 2 31 & 32

Alarm 3 33 & 34

Alarm 4 35 & 36

Common Alarms All of the following conditions will cause a common alarm -

ADC Calibration Fail

DAC Calibration Fail

Sensor 1 Fail

Sensor 2 Fail*

Heater 1 Fail

Heater 2 Fail*

Sensor 1 TC Open

Sensor 2 TC Open*

Aux. TC Open

Reference Air Pump Fail

Reference Air Fail **

Mains Frequency Check fail

Probe Filter Blocked

Gas 1 Calibration Check Error

Gas 2 Calibration Check Error

Burner bypass Switch on

Oxygen Deviation High*

BB RAM Fail

Watchdog Timer

* These alarms are only available if two sensors are selected

** This alarm is only available if a flow sensor is installed in CN8 on the 1630-2 PCB

The watchdog timer is a special alarm. It will force the common alarm to activate in the event of a microprocessor

failure. There will not be an alarm message displayed, but the transmitter will reset.

OXYGEN

TYPE K THERMOCOUPLE

HEATER 110VAC 100 WATTS

+

-

+

+

-

-

F BLUE

D WHITE

E WHITE

C ORANGE

B BROWN

A BLACK

August 2007


Mains Voltage 110/240 VAC

From terminals 43 & 44

Calibration Check Gas Flowmeter/Regulator

5 litres/min (10 scfh)

To Oxygen Probe

‘CAL’ port

Clean & Dry Purge

Air Supply

140 kPa max (20psi)

CAL Check Gas #1

140 kPa max (20psi)





CAL Check Gas #2

140 kPa max (20psi)

Mains Voltage 110/240

AC Solenoids

Cal 2 Sol 46

Purge Sol

Purge Sol

Cal 1 Sol

Cal 1 Sol

Cal 2 Sol 45

43

44

41

42

Alarms can be accepted by either pressing the alarm button (viewing the alarm messages), or by temporarily closing a

switch connected to terminals 16 & 17, REM ALARM RESET.

Alarm relay 2 to 4 Select any one or all of the following for each relay. Refer 5 to Section 5.5, steps 70 to 81

High oxygen

Low oxygen

Very low oxygen

Probe or sensor under temperature

Calibration check in progress

Probe purge in progress

Alarm horn function (Relay 4 only)

3.11 CONNECTING THE AUTOMATIC PURGE AND CALIBRATION CHECK

SYSTEM

CAUTION The purge and calibration solenoid valves are supplied with mains voltage. This supply has electrical shock danger to

maintenance personnel. Always isolate the transmitter before working with the purge and calibration solenoid valves.

The on-line auto purge and calibration check system is optional. For details on its operation refer to Sections 1.3, 1.4,

2.9 and 2.10.

To automatically sense a blocked probe filter, a pressure sensor should be connected to the ‘purge’ line to the probe

‘cal’ port. It should be adjusted so that it energises just above the purge pressure with a new or clean filter installed.

The switch contacts should be connected to terminals 12 & 13 (PURGE FL SWITCH).

If the filter is still blocked or partly blocked after an auto purge cycle, the pressure switch will energise and cause a

‘Probe Filter Blocked’ alarm.

After installation the purge/cal system should be tested thoroughly for leaks. Any leaks can cause significant errors if

the flue is at negative pressure. If the flue is at positive pressure, an outward leak can cause corrosion in the purge/cal

system piping and fittings.

If probe/filter purging is required but a “Probe Filter Blocked” alarm is not required, link terminals 12 &13.

Automatic Purge &

Calibration check System

Wiring Schematic

Automatic Purge &

Calibration check System

Piping Schematic

August 2007


3.12 CONNECTING REFERENCE AIR For 1234 sensors, no reference air connection is required. For oxygen probes, a 1/4” tube connector on the transmitter

should be connected via a nylon, copper or stainless steel tube the to ‘REF’ connector on the probe.

If two probes are being used, a “T” union must be supplied to provide reference air supply to both probes.

If ‘Internal’ is selected in set-up 85, and a reference airflow sensor is connected to CN8 on the 1630-2 (terminal) PCB,

the reference air pump is cycled on and off each minute.

3.13 CONNECTING THE DUAL FUEL INPUT If combustibles or maximum carbon dioxide display is required and the appliance is capable of firing more than one

fuel, then an external contact must be connected for the transmitter to determine which fuel is being burnt.

Fuel Selector Input Contact Connection

3.14 CONNECTING THE PRINTER A printer with a serial port, or a data logger, or a computer terminal may be connected to RS 232-C or the network port.

Data is logged out of the port as arranged in Set-up steps 82 and 83. The baud rate is selectable in set-up step 84. The

RS-232 protocol for the serial port is eight data bits, one stop bit, no parity.

Serial Port Connections

Contacts to be open FUEL 1

is running and closed when

FUEL 2 is running

14

15

FUEL 1/2

Available for

RS 485 network

PRINTER OR DATALOGGER

Ser Com24

Network -

Network +23

22

RS 232 Rx

RS 232 Tx

20

21

August 2007


3.15 CONNECTING THE TRANSMITTER TO A MODBUS™ NETWORK The transmitter can be networked to other transmitters and to a network master. The network uses the transmitter’s

RS485 port. Up to 31 transmitters can be connected to the network, and can be interrogated by the Network Master.

NOTE: Hardware Protocol Selection

For the RS485 port on the transmitter to operate, the link LK3 on the 1630-1 printed circuit board (mounted on the door

of the transmitter) must be set to the RS485 position. The LK3 is accessed by removing the cover from the door PCB. It

is located at the bottom of the circuit board.

NOTE: Terminating Resistor

There is a terminating 100 ohm resistor fitted to the 1630-1 PCB. Link LK2, in the bottom left-hand corner of the PCB

on the door, is used to connect the terminating resistor. Link LK2 must be removed on all transmitters except the

transmitter on the end of the network line. If the network line from the transmitters is taken from the middle of the

transmitter network string, a terminating resistor should be enabled with LK2 at each end of the network line.

The protocol of the network is – Baud Rate 9600

Parity none

Stop Bits 1

RS485 Half Duplex

Mode RTU (binary mode)

For more details see Section 2.12 and Appendix 6.

Network Connections

Network -

Network +

Network Com.

22 Network -

23 Network +

24 Network Com

Oxygen Transmitter #1

22 Network -

23 Network +

24 Network Com

Oxygen Transmitter #2

22 Network -

23 Network +

24 Network Com

Oxygen Transmitter 31

Network Master

August 2007


COMMISSIONING

3.16 CONNECTING POWER Before commissioning the probe, sensor or transmitter, read the CAUTION paragraphs at the front of this manual.

Check that the mains supply voltage switch is set for the correct supply voltage, and that the green/yellow EARTH wire

MUST be connected to earth.

3.17 COMMISSIONING - SET-UP MODE Press the SET-UP button to select the ‘SET-UP’ mode. Most of the default settings of the functions will be correct, or

will have been pre-set at the factory. Refer to Section 5.5 for more details.

Check the following set-up functions -

2 to 6 Date /time

7 to 10 Reference voltages

11 & 12 Probe offset

22 & 23 Sensor type

26 & 27 Output channel #1

28 to 30 Output channel #2

53 Auto purge

67 Auto gas calibration checking

70 to 78 Alarm set-up

3.18 COMMISSIONING - RUN MODE When the transmitter is turned on it will go to RUN mode. The SET-UP/RUN button will toggle between the two

modes. The upper line of the display will now read ‘% OXYGEN’. If the probe or sensor temperature is not above

650°C (1200°F), a “Probe Low Temperature” message is flashed on the lower line. The probe or sensor temperature

can be checked on the lower line of the display.

3.19 BURNER BY-PASS SWITCH Heated probes and sensors should have their heater supply interlocked. If the combustion appliance is not running, then

power will not be supplied to the heater. To commission an oxygen probe when the main burner is turned off, switch

power off the transmitter, remove the probe from the flue or the flue connection from the 1234 sensor.

Re-apply power to the transmitter, press the BURNER BY-PASS switch into the ‘DOWN’ or ‘ON’ position. This will

apply power to the probe or sensor heater even when the plant is not running. The offset can now be set and calibration

checked with appropriate calibration check gases (typically 2% oxygen in nitrogen).

Ensure that the burner by-pass switch and the power are turned off before the probe or sensor is re-installed. An alarm

will occur if the BURNER BY-PASS switch is turned on (down) during normal operation.

3.20 CHECKING THE ALARMS If any alarms are present the alarm LED will be lit, either flashing or steady. To interpret the alarms, press the alarm

button until all alarm functions have been displayed. Rectify the cause of each alarm until no further alarms appear on

the display. For details on the operation of the alarm button and the alarm functions refer to Section 4.

3.21 PROBE OR SENSOR CALIBRATION The zirconia sensor provides an absolute measurement of oxygen partial pressure. There are no calibration adjustments,

apart from ‘SENSOR OFFSET’, for the probe or sensor. The zirconia sensor EMF is either correct or replacement is

required. To check that the probe or sensor is functioning correctly, firstly check that the high impedance alarm,

‘SENSOR FAIL’, is not active. The actual impedance can be displayed on the lower line. It should be less than 9 KΩ at

720°C (1320°F).

Once it has been established that the impedance is normal, the offset may be set using the millivolt level marked on the

oxygen probe or sensor. Refer to Section 5.5.11. The probe offset can be tested on site. A small flow of air must be

admitted to both the ‘REF’ and ‘CAL’ ports when testing the probe offset. If the probe is in the process, the air must

fully purge the probe sensor without interference from the process gas sample. Novatech probes can easily achieve this

August 2007


with or without a probe filter and a gas flow of only 1 to 5 litres/minute (120 to 600 scfm) for a 1231 probe and up to 20

litres/minute (2400scfm) for an unheated probe.

3.22 FILTER PURGING Purging probe filters is controlled from the ‘PURGE’ button on the transmitter when in ‘RUN’ mode. If ‘AUTO

PURGE’ has been enabled in set-up 53, pressing the PURGE button will start the automatic cycle. Pressing any other

button will cancel the auto purge cycle. If AUTO PURGE was not enabled, the purge solenoid will only stay open for

as long as the button is pressed. Gradually adjust the purge air supply regulator, increasing the pressure until sufficient

flow is obtained to clear the filter. This is best checked with a dirty filter after a period of operation, by withdrawing the

probe from service and watching any build up on the filter being blown off at the set pressure. Normally 30 kPa (5 psi)

is adequate but the air pressure may be set as high as 100 kPa (15 psi).

3.23 CALIBRATION GAS CHECK If the installation has a filter purge facility, set this up first. Refer to the previous paragraph. Press the ‘CAL 1 or ‘CAL

2’ button while in ‘SET UP’ mode to obtain a reasonable flow through the calibration check gas flow meter. If air is

being used as a calibration check gas, use the air from the regulator for filter purge. Then, when setting up a gas for

calibration checking, set the pressure from the calibration gas cylinder so that it is the same as the pressure set on the air

regulator. Then the setting on the rotameter / flow regulator will be the same as that for the airflow. The flow required

is 1 to 5 litres/minute (120 to 600 scfm) ) for a 1231 probe and up to 20 litres/minute (2400scfm) for an unheated probe.

Air is not the best gas for calibration checking on a zirconia sensor. The output of a zirconia sensor with air on both

sides of the sensor is zero millivolts. It is better to choose a gas value which provides a reasonable output from the

sensor and which is near to the process oxygen level. A cylinder with 2% oxygen in nitrogen is a commonly used

calibration gas. The maximum pressure on the calibration check gas cylinder regulators is 100 kPa (15 psi).

Note: If two probes was selected in set-up 1, ‘Cal Gas 2’ must be connected to probe 2.

3.24 DUST IN THE FLUE GAS For unheated probes with no filter, entrained solids or dust in the flue gas does not present a problem unless the dust,

when settled, is not porous. Allow the dust in the process to build up on the probe. It will form a porous layer slowing

the response time. To avoid mechanical abrasion of the electrode material in installations with unheated oxygen probes,

pack ‘SAFFIL’ or equivalent alumina based ceramic fibre in the sensing holes to protect the electrode. Do not use silica

based ceramic fibres such as ‘KAOWOOL’, which can attack the electrode at high temperatures. Once the dust has built

up the response time of the probe will be slower.

For heated probes the preferred method of mounting for dust-laden applications is facing vertically downwards with the

filter removed. Probes can also be mounted horizontally with no filter with some dusts. An occasional automatic back

purge is helpful in this case.

Normally heated probes are supplied with filters for applications with particulates in the flue gas. The probe response

time should be tested when the probe is first installed, and then regularly until it remains constant for a significant

period. Filter purging should be set up on the time periods determined by these tests. To test the probe response time,

use a stopwatch to obtain the time for a probe to achieve a 63 % change from one reading to another. If a probe filter

blocks completely in a short period of time, then there is no option but to use the probe without the filter. A trial probe

with filter can be installed to test whether a filter blockage is likely to occur.

3.25 STRATIFICATION If the transmitter and probe have been fully tested and the oxygen readings in the flue gas are incorrect, gas stratification

may be occurring. The phenomena cannot be anticipated for any particular installation. Generally, large flues have

oxygen differences of approximately one percent across the flue. Occasionally an oxygen error of several percent may

occur in a flue of any size. Moving the probe to a new location normally solves this problem.

The effects of stratification can be reduced by using two probes and averaging the two oxygen readings. This can be

achieved within a Novatech 1632 transmitter controlling two probes.

August 2007


3.26 CONNECTING A PRESSURE TRANSDUCER If the process gas pressure varies more than 4” WG and therefore requires dynamic compensation, connect a pressure

transducer as shown below. Place the link on LK1 in the 4-20mA position, this connects an on-board 47Ω resistor to

terminals 8 & 9. A pressure change of 4” WG will cause an oxygen error of about 1% of the oxygen reading.

Pressure Transducer Connection

There are no adjustments for the zero or span of the pressure transducer input and the pressure cannot be displayed on

the lower line. However the input calibration can be checked with the following procedure.

Note: This procedure will check that the 4-20mA input will transfer correctly to an oxygen value that is correctly

compensated for pressure. The zero and full scale pressure range of the transducer does not have to be used for the

calibration. Because the scaling is manipulated digitally, the scale can be changed to suit the pressure transducer after

the calibration.

1. Configure the set-up options as below –

34. Flue Pressure Setup- “Variable Input”

35. Flue Pressure Input Zero Value- 0 mb

36. Flue Pressure Input Span Value- 1000 mb

2. Connect a 4-20mA generator to the input terminals 8 & 9. Make sure that the 47 ohm resistor is across the input

terminals 8 & 9.

3. Connect either an oxygen probe or a mV generator to simulate 2% oxygen. This will require 50.26mV between

terminals 1 (+) and 2 (-), and 29mV between terminals 3 (+) and 4 (-). Adjust the 29mV until the transmitter reads

720 °C when selected on the lower line.

4. Set the 4-20mA generator to 4mA. The transmitter should read 2.0% oxygen.

5. Set the 4-20mA generator to 20mA. The transmitter should read 1.00% oxygen.

If the oxygen values do not read as indicated in numbers 4 and 5 above, check –

(a) The set-up items 34, 35 and 36 are set as stated in number 1.

(b) The polarity of the input signal.

(c) The oxygen level with the 4-20mA generator disconnected. It should be 2.0%.

Connect a 4-20mA pressure

transducer. Set the range of the

transducer in the set-up mode.

8

9 - RGC I/P

+ RGC I/P

47 Ohm resistor

August 2007


August 2007


OPERATOR FUNCTIONS

4

SECTION

NUMBER

4.1 DISPLAY BUTTON

4.2 ALARM BUTTON

4.3 ALARM SCHEDULE

4.4 POWER LAMP

4.5 BURNER BYPASS SWITCH

4.6 DISPLAY BACKLIGHT

August 2007


OPERATOR FUNCTIONS (RUN MODE)

4.1 DISPLAY BUTTON The upper line on the display will always read % oxygen (or ppm, selectable in step 31 in the set-up menu Section 5.5)

for sensor 1. The following are available for display on the lower line.

1. AVERAGE OF PROBE 1 & PROBE 2 OXYGEN,

2. PROBE 2 OXYGEN,

3. PROBE 1 EMF (millivolts)

4. PROBE 2 EMF (millivolts)

5. PROBE 1 TEMPERATURE

6. PROBE 2 TEMPERATURE

7. PROBE 1 IMPEDANCE,

8. PROBE 2 IMPEDANCE, A measure of integrity of the sensor's electrode, the part of the probe that normally wears

out first.

9. AUXILIARY TEMPERATURE

10. AMBIENT TEMPERATURE

11. OXYGEN DEFICIENCY %

12. COMBUSTIBLES %

13. % CARBON DIOXIDE, dry. Calculated from the oxygen reading. Assumes complete combustion.

14. RUN HOURS SINCE LAST SERVICE

15. DATE OF LAST SERVICE

Any number of these variables can be displayed sequentially by pressing the ‘DISPLAY’ button. Items can be selected

for display or deleted in step 33, in the set-up menu Section 5.5, on the keyboard. In addition to the above lower line

displays, the transmitter will automatically display:

“Sensor 1 Temp Low”, when sensor one is below 650°C (1200°F)

“Sensor 2 Temp Low”, when sensor two is below 650°C (1200°F)

“Gas 1 ON”, “Gas 2 ON” for Calibration check Gas 1 or 2

“Purging Probe”

“Sensor 1 Thermocouple Wrong Polarity”

“Sensor 2 Thermocouple Wrong Polarity”

“Aux Thermocouple Wrong Polarity”

NOTE: 1. The run time will be the period of time the BURNER ON SWITCH (terminals 18 & 19) contact is closed (ie. main

fuel valve open). If no explosion protection is required, a permanent bridge between the BURNER ON SWITCH

terminals will register run time whenever the transmitter is powered.

2. This timer can be used as a probe replacement and/or boiler service schedule aid. Changing the ‘SERVICE DAY’ in

set-up mode on the keyboard resets the start time.

3. If you hold the display button down as you switch on the power, the maximum ambient temperature which the

instrument has been subjected to, will be displayed. This temperature should be less than 50°C (130°F).

August 2007


4.2 ALARM BUTTON Repeatedly pressing the ‘ALARM’ button will produce alarm displays in sequence on the lower line of the LCD display.

If an alarm has cleared prior to pressing the ‘ALARM’ button, it will not re-appear on a second run through the alarms.

Active alarms which have been previously displayed will have ‘acc’ (accepted in lower case), displayed alongside. New

alarms will not have ‘ACC’ (in upper case) displayed until a second press of the ‘ALARM’ button. After the last active

alarm is indicated, the lower line of the display will return to the last displayed lower line variable. Alarms may also be

accepted remotely by a temporary closure of a switch connected to terminal 16 & 17, ‘REMOTE ALARM RESET’.

The alarm ‘LED’ will flash when there is an un-accepted alarm. Pressing the ‘ALARM’ button will cause the LED to go

steady if any alarms are still active, or extinguish if there are no active alarms. The horn relay will operate when an

alarm occurs. Pressing ‘ALARM’ will mute a horn relay (if one of the user configurable relays have been selected as a

‘Horn’ relay) which will re-initiate on any new alarms.

4.3 ALARM SCHEDULE

4.3.1 SUMMARY OF ALARMS - COMMON ALARM

1. ‘Sensor 1 Fail’

2. ‘Sensor 2 Fail’

Oxygen sensor or electrode failure (high impedance); (inhibited under 650°C (1200°F)).

3. ‘Heater 1 Fail’

4. ‘Heater 2 Fail’

In the first 20 minutes of power being applied to the heater after being switched on, this alarm will not occur, but a

‘Sensor 1(2) Lo Temp’ display will occur and common alarm relay will be activated. Refer to Section 6.11. If an ADC

alarms occurs, the heaters will automatically be turned off.

5. ‘Sensor 1 TC Open’

6. ‘Sensor 2 TC Open’

Probe thermocouple is open circuit. The heater in heated probes will switch off.

7. ‘Aux TC Open’

Stack thermocouple is open circuit. If the thermocouple is not needed, select “NO T/C” for “Aux TC Type” or place a

short circuit between terminals 5 & 6.

8. ‘Ref Pump Fail’

The reference air pump in the transmitter has failed.

9. ‘Ref Air Fail’

The reference gas supply from the air pump in the transmitter to the probe is blocked, or there is not sufficient airflow.

10. ‘ADC Cal Fail’

The analog to digital converter has been found to fall outside the normal calibration specifications. In this case the

sensor heater will automatically be turned off.

11. ‘Mains Freq’

The sample of the mains frequency has failed.

12. ‘DAC Cal Fail’

The digital to analog and voltage isolator circuit has been found to fall outside the normal calibration specifications.

This check is only performed when the ‘AUTO CAL’ button is pressed. Refer to Section 6.3.

13. ‘Probe Filter

Blocked probe filter. This test is only performed when automatic purging of the probe is selected. Refer to step 53 in

the set-up menu Section 5.5. This alarm will not reset until the next purge cycle that can be initiated manually or

automatically.

14. ‘Gas 1 Cal Err’

Probe does not correctly calibrate to calibration check gas 1.

August 2007


15. ‘Gas 2 Cal Err’

Probe does not correctly calibrate to calibration check gas 2.

16. ‘Burner bypass’

The safety interlock relay has been bypassed by turning on the ‘BURNER BYPASS’ switch on the terminal printed

circuit board. Refer to Section 3.19

17. ‘Oxygen Deviation High’

The oxygen as read by sensor 1 differs from the oxygen read by sensor 2 by an amount greater than the level set in step

75 in the set-up menu Section 5.5, for a period longer than that set in step 76. This alarm is only available if ‘Two

Sensors’ is selected in set-up 1.

18. ‘Watchdog Timer’

Microprocessor error. This alarm will not appear on the display. The common alarm relay will be forced open circuit.

If the watchdog timer senses a malfunction in the microprocessor, it will attempt to reset the transmitter every 2 seconds.

After two resets the alarm relay contacts will go open circuit.

19. ‘BBRAM Fail”

The battery backed memory module has failed in service. The device normally lasts 10 years. It is the plug-in battery

like module on the 1630 -1 board, labelled M1.

20. ‘Htr SSR Fail”

One of the two solid state relays that drive the heaters in the oxygen sensors has failed. The electro-mechanical relay

RL7 will cut off the heater to prevent further damage.

4.3.2 SUMMARY OF ALARMS - SELECTABLE ALARMS

There are three user configurable alarm relays. Any or all of the following functions can be selected for each relay.

NOTE: The process alarms will only be activated if enabled in set-up 70.

21. ‘O2% Low’

The measured oxygen level is below the level set in set-up 73, and the alarm delay set in set-up 74 has expired. See step

64 in the set-up menu Section 5.5 for more details.

22. ‘O2% Very Low’

The measured oxygen level is below the level set in set-up 77, and the alarm delay set in set-up 78 has expired. See step


23. ‘O2% High’

The measured oxygen level is above the level set in set-up 71, and the alarm delay set in set-up 72 has expired. See step


24. ‘Probe Temperature’

The probe temperature is under 650°C (1200°F). The oxygen reading is therefore invalid. If the probe heater has been

on for more than 20 minutes and the temperature is less than 650°C (1200°F) a ‘heater fail’ alarm will occur.

NOTE:

The ‘Probe Temp’ relay function is used with unheated probes to indicate oxygen reading is invalid (the probe is below

650°C (1200°F) ), in case the process temperature falls below this level. With heated probes this relay will be de-

energised while the probe is heating up from ambient, making the contacts open circuit.

25. ‘Cal in Progress’

A calibration check is occurring, either manual ( in RUN mode) or automatic

Probe Purge

A probe purge is occurring, either manual ( in RUN mode) or automatic

26. Alarm Horn

This is not an alarm condition. If one of the three user configurable alarm relays have ‘Alarm Horn’ enabled; the relay

will have closed contacts only when there is an unaccepted alarm on the transmitter. Press the alarm button twice to

accept any new alarm and to cancel the horn relay. This is only available on relay 4.

August 2007


4.3.3 ALARM RELAYS

The alarm relays are fail safe. That is, the contacts will be closed during normal operation, and will be open circuit if

there is an alarm or if the power is removed from the transmitter.

4.4 POWER LAMP Illuminates when power is connected to the transmitter. If the lamp is flashing, the watchdog timer is attempting to reset

the microprocessor. Replace the 1630-1 microprocessor PCB.

4.5 BURNER BYPASS SWITCH This switch is mounted on the terminal PCB near the POWER switch.

Before the heater in a heated probe, or the alarms will be enabled, the probe must be enabled. There are two ways of

doing this.

Use the safety interlock on terminals 18 & 19 (BURNER ON switch), or press the BURNER BYPASS switch to the ON

position. While the BURNER BYPASS switch is on there will be an alarm, “Burner Bypass”.

If it is not needed to have the transmitter interlocked with the combustion appliance terminals 18 & 19 can be connected

together.

4.6 DISPLAY BACKLIGHT If the ambient temperature measured inside the transmitter cabinet exceeds 35°C, the backlight will be turned off one

minute after the keypad is used. This is aimed at reducing one of the major sources of heat within the cabinet when the

ambient temperature is high. The backlight will come on again as soon as a button is pressed.

The internal reference air pump (if fitted) will start cycling on and off every minute, above 35°C.

August 2007


August 2007


SETTING UP THE

TRANSMITTER

5

SECTION

NUMBER

5.1 SET-UP MODE SUMMARY

5.2 SET-UP & RUN MODES

5.3 FUNCTION SELECT

5.4 ENTER OPTION OR VALUE

5.5 SET-UP FUNCTION DETAILS

August 2007


SET-UP MODE SUMMARY

5.1 SET-UP MODE FUNCTIONS

1 Number of Sensors

2 Calendar Year

3 Calendar Month

4 Calendar Day

5 Real time clock Hour

6 Real time clock Minutes

7 Reference voltage #1




11 Sensor 1 offset

12 Sensor 2 offset

13 Output channel number 1 calibration

14 Output channel number 1 calibration, 4mA trim


16 Output channel number 2 calibration



19 Service record year

20 Service record month

21 Service record day

22 Sensor 1 Type

23 Sensor 2 Type

24 Sensor 1 Thermocouple Type

25 Sensor 2, Auxiliary Thermocouple Type

26 Transmitter Output Channel 1 scale

27 Transmitter Span Channel 1

28 Transmitter Output Channel 2 scale

29 Transmitter Zero Channel 2

30 Transmitter Span Channel 2

31 Top Line Display Units, % or ppm

32 Centigrade/Fahrenheit Selection

33 Lower Line Display Functions

34 Flue Pressure, Fixed/Variable

35 Flue Pressure Input Zero Level

36 Flue Pressure Input Span Level

37 Flue Pressure mm/inches/kilopascals

38 Flue Pressure Value

Set-up steps 39 to 51 will be skipped automatically if combustibles, maximum CO2 or oxygen deficiency are not

selected in steps 28, 33 or 82.

39 Single or Dual Fuel

40 Fuel #1 ‘A’ Value

41 Fuel #1 ‘H’ Value

42 Fuel #1 ‘O’ Value

43 Fuel #1 ‘N’ Value

44 Fuel #1 ‘S’ Value

45 Fuel #1 ‘M’ Value

Set-up steps 46 to 51 will be skipped automatically if ‘Single Fuel’ is selected in set-up step 39.

46 Fuel #2 ‘A’ Value

47 Fuel #2 ‘H’ Value

48 Fuel #2 ‘O’ Value

49 Fuel #2 ‘N’ Value

50 Fuel #2 ‘S’ Value

51 Fuel #2 ‘M’ Value

August 2007


52 Purge/Cal Time

53 Automatic Purge

Set-up steps 54 to 56 will be skipped automatically if ‘No’ is selected in set-up step 53.

54 Time between Purges

55 Purge Duration

56 Purge Freeze Time

57 Number of Cal Gases

Set-up steps 58 to 69 may be skipped automatically, depending on the selection in set-up step 57.

58 Oxygen Content of Cal Gas 1

59 Maximum Acceptable Positive Error Gas 1

60 Maximum Acceptable Negative Error Gas 1

61 Period Between Gas 1 Autocals

62 Duration of Autocal Gas 1

63 Freeze Time Gas 1

64 Oxygen Content Of Cal Gas 2

65 Maximum Acceptable Positive Error Gas 2

66 Maximum Acceptable Negative Error Gas 2

67 Period Between Gas 2 Autocals

68 Duration of Autocal Gas 2

69 Freeze Time Gas 2

70 Process alarm enable

Set-up steps 71 to 78 will be skipped automatically if ‘No’ is selected in set-up step 70.

71 High oxygen alarm level

72 High oxygen alarm delay time

73 Low oxygen alarm level

74 Low oxygen alarm delay time

75 Oxygen Deviation Alarm (2 probes)

76 Oxygen Deviation Alarm Delay (2 probes)

77 Very low oxygen alarm level

78 Very low oxygen alarm delay time

79 Alarm relay number 2 function select



82 Data to Print

83 Print Log Period

84 Printer Baud Rate

85 Reference air pump Internal/External/Inst air

86 Reference air RH if ‘Instrument Air’ selected in Set-up 85.

87 Damping factor

88 MODBUS™ Address

The “Extended Set-up Menus” steps 89 to 97 will be skipped unless the extended menus are enabled. See Set-up 5.2 for

more details.

89 Reference pump cycle time.

90 Low oxygen calibration factor, sensor #1.

91 Low oxygen calibration factor, sensor #2.

92 Gas calibrate / check selection.

93 Oxygen mid point calibration factor #1.

94 Oxygen mid point calibration factor #2.

95 4-20mA output limit enable option.

96 Solid state relay fail alarm setting.

97 Heater solid state relay swapping function.

August 2007


5.2 SET-UP & RUN MODES For the SET-UP mode keyboard to operate, press the SET-UP/RUN button. The set-up light will come on when the set-

up mode has been entered.

NOTE:

Set-up mode cannot be entered if the keyboard lock switch (SW1) on the inside of the transmitter is in the UP position.

The keyboard lock switch can be found on the door PCB (1630-1), on the lock side, at the top. If access is attempted

while the keyboard is locked, the message ‘Illegal Access’ will be displayed.

While the transmitter is in set-up mode the outputs will be frozen. All of the functions written in BLUE will now

operate. If there are not any buttons pressed for 1 minute the transmitter will automatically revert to RUN mode.

If purges or an auto-calibration check occurs while the transmitter is in set-up mode, they will be delayed until the

transmitter is returned to RUN mode.

To cancel an automatic purge or calibration check cycle, press AUTO CAL button while in RUN mode.

The Extended Menus can be seen if the Setup button is pressed before power is applied to the transmitter, and held until

the display shows the words “Extended Menu”.

5.3 FUNCTION SELECT When the SET-UP mode is entered, the transmitter will automatically read the last set-up function selected.

To select other functions, operate the ‘FUNCTION ’ button to increment to the next function, or ‘FUNCTION ’ to

decrement to the previous function.

5.4 ENTER OPTION OR VALUE

A. Options. To step through the available options for each function press the ‘OPTION ’ or ‘OPTION ’ buttons.

When the required option is selected press the ‘ENTER’ button. An asterisk will then appear alongside the option

selected. When stepping through the set-up functions, the display will always first indicate the last options entered. The

‘Lower Line Select’ and ‘Data To Print’ set-up items 33 and 82 are multiple options. One or more options may be

selected for these functions.

B. Values To set a value for a particular function press the ‘OPTION ’ button to increase the value and the ‘OPTION ’ button

to decrease the value. A momentary press will change the value one digit. Holding the button will change the value

more quickly. Once the correct option or value is displayed it can be entered into the transmitter's memory by pressing

the ‘ENTER’ button. When a value has been entered an asterisk will appear at the R.H.S. of the lower line.

1632 Oxygen TRANSMITTER Keyboard

Oxygen 2.04% *

EMF 1 mV 49.8

CAL 1

FUNCTIO

N

CAL 2

OPTION

PURGE

ENTER

Z TEST AUTOCAL

SETUP

RUN

ALARM

OPTION

DISPLAY

FUNCTIO

POWER ALARM SETU

August 2007


5.5 SET-UP FUNCTION DETAILS

Note: The * indicates the default setting after a COLD-START. See Section 6.1

1. Number of sensors Options

Select the number of oxygen probes or sensors being used.

1 Sensor *

2 Sensors

2. Calendar year Options

Select the current year for the real time clock / calendar.

The cold start default sets the date and time to the software version date.

3. Calendar month Options

Select the current month for the real time clock / calendar.

4. Calendar day Options

Select the current day for the real time clock / calendar.

5. Real time12:20:53 PM clock hour Options Select the current hour for the real time clock. (24 hour format)

6. Real time clock minutes Options

Select the current minutes for the real time clock.

7. Reference voltage # 1 (about 27.5 mV) Options

Set the value of the reference voltage as read on a 3 1/2 digit multimeter (See Section 6.2 for further details).

27.55 mV *

8. Reference voltage # 2 (about 194 mV) Options


193.60 mV *



1202.00 mV *



2479.00 mV *

Set-up items 7 to 10 are used to calibrate the A/D of the instrument. This should be done 30 minutes or more after the

instrument has been on, approximately once every year. The calibration constants are retained in battery backed

memory unless a ‘COLD START’ is performed. Connect a 3 1/2 digit multimeter negative lead to the test point marked

‘C’ to the right of the PCB on the inside of the door (labelled ‘REF VOLTS’). Measure the four voltages on the test

point marked 1 to 4 with the positive lead. Refer to Figure 6.2 in the 1632 manual. Enter the measured values in set-up

items 7 to 10. Whenever new values are entered the D/A Section should be re-calibrated, Refer to Section 6.3.

August 2007


11. Set Probe or Sensor 1 Offset See function 12

12. Set Probe or Sensor 2 Offset (When 2 sensors are selected in set-up 1)

A new EMF offset must be entered whenever a new oxygen probe or sensor is installed to calibrate for any offset an

individual probe or sensor may have. Each probe or sensor will have an offset value noted on a removable tag. Enter

the ‘SENSOR OFFSET’ value with the same polarity,

eg. if offset value is -1.2 mV. enter -1.2 mV. The typical maximum is +/- 2mV.

To check a probe offset on site, the probe must be sensing air, with reference air, and allowed to settle at the probe

operating temperature for 30 minutes. Read the offset in ‘RUN’ mode in millivolts on the lower line. Offset errors can

occur if the sensor does not have some air passing over it. A gentle flow of air in the calibration check port can be

provided by a reference air pump or similar.

For heated probes, if the combustion appliance is not operational and the probe heater is interlocked with the ‘BURNER

ON’ signal, the ‘BURNER BYPASS’ switch should be set to ‘ON to power the probe heater after removing the probe

from the flue.

CAUTION DANGER

Return the ‘BURNER BYPASS’ switch to normal (off) before installing the probe in the flue.

For unheated probes, the probe sensing tip must be raised to at least 650°C (1200°F) with a portable furnace.

Determine the probe offset in ‘RUN’ mode. Select ‘Sensor EMF’ on the lower line. With probe in air, stabilised at

temperature for 30 minutes, read the ‘Sensor EMF’. Switch back to ‘set-up’ mode and enter ‘Sensor Offset’ of equal

value and the same polarity.

eg. If the measured ’SENSOR OFFSET’ was -1.2 mV, enter -1.2 mV.

When reading the EMF offset, the flue pressure compensation must be set. If the probe has been removed from the flue,

set the flue pressure compensation set up to “Fixed” in set-up 34, and the value to 0 in set-up step 38.

13. 4 to 20 mA Calibration Options, Channel #1 Select the calibration method for the 4-20mA output channel #1.

The output channels can be either calibrated by simply pressing the ‘AUTO CAL’ button, or can be trimmed at both the

4mA and 20mA ends of the scale using an external multimeter.

Options:

1. Auto Calibration *

2. Manual Calibration

3. Set 4mA Trim

4. Set 20mA Trim

If ‘AUTO CAL’ is selected, the output channel is calibrated when ‘Auto Cal’ is initiated from the keyboard (See Section

6.3).

If ‘MAN CAL’ is selected, it is necessary to trim both ends of the 4-20mA output range using the 4mA and 20mA

options in this menu item. Selecting ‘MAN CAL’ inhibits the ‘Auto Cal’ process of this channel.

Always do the 4mA trim first, and then the 20mA trim. After trimming both ends of the scale, return the

‘CALIBRATION OPTIONS’ menu option back to ‘MAN CAL’ (not ‘AUTO CAL’), or the calibration factors will be

over written by the next ‘AUTO CAL’.

For more details on calibrating the output channels, see Section 6.3.

NOTE: The transmitter will only stay in either ‘4mA TRIM’ or ‘20mA TRIM’ modes for 30 minutes before it

automatically returns to ‘MAN CAL’.

14. Calibrate 4mA, Channel #1 This menu item only appears if ‘Set 4mA Trim’ is selected in Set-up 13.

Range: 0 to 25mA, Default is 4.00mA

For full details on the calibration of the 4-20mA output channels, see Section 6.3.

August 2007




16. 4 to 20 mA Calibration Options, Channel #2 Select the calibration method for the 4-20mA output channel #1.

For more details, see Set-up 13 and Section 6.3.

Options:

1. Auto Calibration *

2. Manual Calibration

3. Set 4mA Trim

11. Set 20mA Trim



For full details on the calibration of the 4-20mA output channels, see Section 6.3.



19. Enter Service Year For a new ‘DATE OF LAST SERVICE’, enter the service ‘YEAR’. This can represent the last time the probe or sensor

was serviced or the last time the boiler was serviced. It is recommended that probes and sensors be refurbished every

two years

20. Enter Service Month Enter the current ‘MONTH’.

21. Enter Service Day Enter the current ‘DAY’ of the month. Altering these values will reset the ‘RUN TIME’.

22. Sensor 1 Type

23. Sensor 2 Type Options:

Model No. Enter the probe or sensor model number in use

1. 1231/1234 Heated * Heated Probe or sensor

2. 1232 Unheated Unheated Probe

24. Probe or Sensor 1 Thermocouple Type See function 25

August 2007


25. Probe or Sensor 2 Thermocouple Type (When 2 sensors are selected in set-up 1)

Auxiliary Thermocouple Type (When 1 sensor is selected in set-up 1) The probe can have either a type K, or R thermocouple as a sensor temperature detector. A 1231 probe or a 1234 sensor

will always have a K thermocouple, and a 1232 will usually have an R thermocouple.

Options:

1. K * Check in the manual Section 1

2. R for the probe model number.

3. NO T/C If no TC type is to be used for an Auxiliary use.

NOTE

For heated probes the flue (auxiliary) thermocouple is a separate sensor from the oxygen probe and should be mounted

near to and upstream from the probe. It is optional. If no thermocouple is required, select option ‘NO T/C’. In this case

auxiliary temperature read outs will not be operable.

26. Transmitter Output Channel 1 Select the type of output required from Channel 1. Linear is the most common output required. The logarithmic output

is often used when connected to an analog indicator that will then give an exploded view of the oxygen range near the

normal operating level. You can draw your own scale using data in Appendix 3.

Options:

1. Linear Oxygen Average (Sensor 1 & 2) (When 2 sensors are selected in set-up 1)

2. Linear oxygen Sensor 1 * (When 1 sensor is selected in set-up 1)

3. Logarithmic oxygen, sensor 1

4. Reducing oxygen, sensor 1, Range fixed at 10-1 to 10-30 % oxygen

5. Reducing oxygen, sensor 1, Range fixed at 10+2 to 10-4 % oxygen (100% to 1ppm)

6. Very low linear oxygen sensor 1, 0 to 0.001 to 2.0% (10 to 20,000ppm)

7. Oxygen deficiency, sensor 1. Range fixed at –5 to +20%.

The reducing output is for special applications requiring extreme reducing conditions eg. ceramic surface treatment.

Linear output spans are adjustable in Set-up step 27. The logarithmic output is fixed at 0.1 to 20 % oxygen and the

reducing output is fixed at either 10-1 to 10-30 % oxygen or 10+2 to 10-4 % oxygen. If either of the latter three are

selected, then set-up 27 will be skipped.

NOTE: If output channel is selected for oxygen, and the temperature of sensor 1 or sensor 2 is below 650°C (the

display will be flashing “NOT READY”) the 4-20mA output for the associated channel will be set to zero mA.

See set-up 91 for further details.

27. Transmitter Span Channel 1 Applicable only to linear outputs. Select transmitter span for output Channel 1. For combustion applications, typical

linear spans are 0 to 10 % or 0 to 15 % oxygen. Very low oxygen range is adjustable from 0 to 0.001, to 2.000%.

Default setting is 10.0%.

28. Transmitter Output Channel 2 Select transmitter output for output Channel 2.

Options:

Sensor EMF 1 *

1. Logarithmic oxygen, 0.1 to 20 %

2. Oxygen deficiency, sensor 1 (or Sensor 2 if 2 sensors are selected in set-up 1)

3. % carbon dioxide dry

4. Auxiliary (Flue) temperature

5. Linear oxygen % sensor 1 ( or Sensor 2 if 2 sensors are selected in set-up 1)

6. 1 x 10 +2 to 10-30 % oxygen sensor 1 (or Sensor 2 if 2 sensors are selected in set-up 1), for reducing conditions.

7. Combustibles %

8. Linear Oxygen Average (Sensor 1 & 2) (When 2 sensors are selected in set-up 1)

29. Transmitter Zero Channel 2 The output zero and span of Channel 2 is set in set-up steps 29 and 30. Range limits are shown below.

August 2007


30. Transmitter Span Channel 2

Output Zero Range Span Range Default Setting

SENSOR EMF 0 to 1100 mV in 100 to 1300 mV 0 to 100 mV

100 mV steps in 100 mV steps

CARBON DIOXIDE 0 to 10 % 5 to 100 % 0 to 100 %

OXYGEN DEFICIENCY +10 to -20 % oxygen 0 to 20% oxygen -5 to +10 % oxygen

(see Note 3) deficiency excess

AUX TEMPERATURE 0 to 1300 °C 100 to 1400 °C 0 to 1300 °C

(32 to 2370°F) (210 to 2550°F) (32 to 2370°F)

in 100° steps in 100° steps

LINEAR OXYGEN 0 to 99.9% 0.1 to100.0% oxygen 0 to 10.0% oxygen

LOG OXYGEN 0.1 % oxygen 20 % oxygen fixed

(see Note 1) fixed

REDUCING OXYGEN 100% to 10 -10 % 10 -3 to 10 -30 % 100% to 10 -30 %

(see Note 2) oxygen in one oxygen in one

decade steps, decade steps. Min

non span five decades

overlapping

COMBUSTIBLES % 0 fixed 0.01 to 2.0 % 0 to 2.0 %

NOTE

1: For log oxygen scale details, Refer to Appendix 3.

2: Note that the reducing oxygen span is shown on the display as the exponent only. -1 represents 10 -1 %

oxygen.

3: The oxygen deficiency output can be used in the same way as a combustibles analyser to signal the extent of

reducing conditions. As an example, if the oxygen deficiency is 3 %, then the burner would need 3 % oxygen

to bring it back to stoichiometry.

4. Always check that the “*” is on the RH end of the lower line to lock in the selection before leaving the function.

5. If output channel is selected for oxygen, and the temperature of sensor 1 or sensor 2 is below 650°C (the display

will be flashing “NOT READY”) the 4-20mA output for the associated channel will be set to zero mA.

See set-up 91 for further details.

31. Top Line Units The oxygen displayed on the top line can be displayed as percent only or auto-ranging to PPM.

If PPM is selected, the display will still read in percent until the oxygen falls below 0.1% when the display will change

to a PPM value, down to 0.1PPM.

Options:

Percent *

PPM

32. Centigrade / Fahrenheit Selection Select whether displays and outputs are to be in ° Celsius or Fahrenheit

Options:

1. Celsius (Centigrade) *

3. Fahrenheit

August 2007


33. Lower Line Display Functions In the run mode the upper line on the LCD display will always read % oxygen. The lower line can be set to read one or

more of the following. Select as many as are required to be displayed by pressing the ‘ENTER’ button. Those selected

will have an asterisk displayed alongside.

Options:

1. Average of sensor 1 & sensor 2 oxygen, see Note 3

2. Sensor 2 oxygen , see Note 3

3. Sensor 1 EMF

4. Sensor 2 EMF, see Note 3

5. Sensor 1 temperature

6. Sensor 2 temperature, or Auxiliary temperature if 1 sensor is selected in set-up 1

7. Sensor 1 impedance

8. Sensor 2 impedance, see Note 3

9. Ambient temperature

10. Oxygen deficiency 1, see Note 2

11. Combustibles %, or oxygen deficiency 2 if 2 sensors are selected in set-up 1.

12. CO2 theoretical maximum

13. Run hours since last service

14. Date of last service

If no lower line options are required then do not enter any. If options already selected are required to be deleted, select

the required option and press the ‘ENTER’ button. The asterisk will be removed.

NOTE

1. A flue thermocouple must be connected to Terminals 5 and 6 to obtain a proper reading for option 9 (Refer Section

3.5).

2. The oxygen deficiency display will read ‘EXCESS’ when the combustion contains excess air.

3. These options will not appear unless two sensors are selected in set up 1.

34. Flue Pressure Setup If the flue or process gas pressure at the position of the oxygen probe is significantly different from atmospheric

pressure, the pressure value should be entered into the transmitter (1 kPa will give an error of about 1% of the oxygen

reading).

If the flue pressure is constant, select “Fixed” in this function and select the pressure units and pressure value in set-up

37 and 38.

If the pressure varies, select “Variable Input”, and connect a pressure transducer to screw terminals 8 & 9 (see Section

3.26). Set the range of the transducer using a zero and span value set in set-up items 35 and 36.

Options:

Fixed *

Variable Input

35. Flue Pressure Zero Input Value Only available if “Variable Input” is selected in set-up 34.

Set the 4mA level if the pressure transducer measuring the flue or process pressure. The default setting is –1000mb.

Limits :

-1000 to +2900mb. The minimum range is 100mb.

36. Flue Pressure Span Input Value Only available if “Variable Input” is selected in set-up 34.

Set the 20mA level if the pressure transducer measuring the flue or process pressure. The default setting is 0mb.

Limits :

-900 to +3000mb. The minimum range is 100mb.

August 2007


37. Flue Pressure Enter flue pressure, eg. 3 mm (0.12”) W.G. Only available if “Fixed” is selected in set-up 34.

Options:

mm W.G. *

Kilopascals

Inches W.G.

38. Flue Pressure Value Enter flue pressure e.g. 3 mm (0.12”) WG. The default setting is 0. Only available if “Fixed” is selected in set-up 34.

Limits :

-3000 to +3000 mm

-3000 to +3000 inches W.G.

-3000 to +3000 kPa

39. Single Or Dual Fuel Enter single or dual fuel. This step and set-up steps 39 to 51 will be skipped if oxygen deficiency, combustibles or

maximum carbon dioxide is not selected in set-up steps 28, 33 or 82 for display or output on the 4-20mA channels or the

printer port.

A set of default values for the fuel constants are loaded into memory. The fuel constants from Appendix can be entered

into the following menu items, or the constants can be tailored to suite any particular fuel.

Options:

1. Single *

2. Dual

40. Fuel Number 1 ‘A’ Value ‘A’ is the heat of combustion of the fuel per gram atom of contained carbon.

Enter the correct value of ‘A’ (Refer notes in Appendix 1).

41. Fuel Number 1 ‘H’ Value ‘H’ is the hydrogen/carbon atom ratio in the fuel.

Enter the correct value of ‘H’ (Refer notes in Appendix 1).

42. Fuel Number 1 ‘O’ Value ‘O’ is the oxygen/carbon atom ratio in the fuel.

Enter the correct value of ‘O’ (Refer notes in Appendix 1).

43. Fuel Number 1 ‘N’ Value ‘N’ is the nitrogen/carbon atom ratio in the fuel.

Enter the correct value of ‘N’ (Refer notes in Appendix 1).

44. Fuel Number 1 ‘S’ Value ‘S’ is the sulphur/carbon atom ratio in the fuel.

Enter the correct value of ‘S’ (Refer notes in Appendix 1).

45. Fuel Number 1 ‘M’ Value ‘M’ is the ratio of water molecules to carbon atoms in the fuel. Enter the correct value of ‘M’ (Refer notes in Appendix

1). For single fuel applications the next set-up step will be 52, for dual fuel the next step is 46.

46. Fuel Number 2 ‘A’ Value ‘A’ is the heat of combustion of the fuel per gram atom of contained carbon.

Enter the correct value of ‘A’ (Refer notes in Appendix 1).

August 2007


47. Fuel Number 2 ‘H’ Value ‘H’ is the hydrogen/carbon atom ratio in the fuel.

Enter the correct value of ‘H’ (Refer notes in Appendix 1).

48. Fuel Number 2 ‘O’ Value ‘O’ is the oxygen/carbon atom ratio in the fuel.

Enter the correct value of ‘O’ (Refer notes in Appendix 1).

49. Fuel Number 2 ‘N’ Value ‘N’ is the nitrogen/carbon atom ratio in the fuel.

Enter the correct value of ‘N’ (Refer notes in Appendix 1).

50. Fuel Number 2 ‘S’ Value ‘S’ is the sulphur/carbon atom ratio in the fuel.

Enter the correct value of ‘S’ (Refer notes in Appendix 1).

51. Fuel Number 2 ‘M’ Value ‘M’ is the ratio of water molecules to carbon atoms in the fuel.

Enter the correct value of ‘M’ (Refer notes in Appendix 1).

52. Purge / Cal Time Set the first purge to occur at the correct time-of-day. If purging is not required but on-line auto gas calibration check is

required, enter a time-of-day value suitable for the auto calibration checks. Cal Gas 1 will be tested ten minutes after the

purge/cal time and Cal Gas 2, 20 minutes after. If neither purge nor auto calibration check is required, ignore this time

setting.

Range: 0 to 23 hours in one hour steps. The default time is 12 noon.

53. Automatic Purge For some oil and coal fired plant, probe filters are necessary and should be back-purged with sufficient frequency to

avoid blocked filters. The outputs will be frozen during purging. If no purge is required, set-up steps 54, 55 and 56 will

be skipped.

Options:

None *

Purge

Auto Offset ++

Key Auto Offset ++

++ Note: If ‘Calibrate’ is selected in set-up step 92 these two additional options will be available.

If Auto Offset is selected, set-up steps 54 to 56 will be available. By using these steps the transmitter can be configured

to make small corrections to the probe offset automatically. The offset correction is limited to +/- 3mV.

If Auto Offset is selected set-up 54 and 55 allow the automatic time periods to be set.

If Key Auto Offset is selected the offset correction can be started from the keypad (PURGE).

54. Time Between Purges Set the time between purges eg. a two hourly purge or a 100 hourly purge.

Range:

1 to 199 hours. Default setting is 24 hours.

August 2007


55. Purge Duration Set up purge duration to a number between three and ten seconds. The filter is actually purged in less than one second,

but three seconds are required for the purge flow switch to check that the filter is not blocked.

Range:

0 to 10 seconds. Default setting is 10 seconds.

56. Purge Freeze Time After the purge period the transmitter output will remain fixed (frozen) for an adjustable period to allow the probe

reading to return to the correct process level and avoid output ‘bumps’. The freeze period time required will depend on

the probe response time and thus its design, and whether it has a filter or not.

To determine the required freeze time, manually perform a purge while the plant is in operation and note the time

required for the reading to return to the correct process level within approximately 0.5 % oxygen.

Range:

10 to 1000 seconds in ten second steps. Default setting is 60 seconds.

57. Number Of Cal Gases Select the number of calibration or checking gases to 0, 1 or 2. For example, one gas could be air (20.9 % oxygen) and

the other 2 % oxygen

Options:

No Gas Check *

Single Gas Check

Two Gas Check

Auto Gas Calibrate ++

Key Gas Calibrate ++

During the timed calibration check periods the transmitter outputs will be frozen and the transmitter will alarm if

readings are not within the accuracy limits sets in set-up steps 59and 60. If auto gas checking is not required enter ‘No

Gas Check’ and the transmitter will step to set-up 70.

++ Note: If ‘Calibrate’ is selected in set-up step 92 these two additional options will be available.

If Auto Gas Calibrate is selected, set-up steps 58 to 63 (and 64 to 69 for 2 probes) will be available. By using these

steps the transmitter can be configured to make small corrections to the calibration automatically. Select the oxygen

content in set-up 58 (64) and the time periods in set-up steps 61 to 63 (67 to 69).

If Key Gas Calibrate is selected the automatic correction can me instigated from the keypad (CAL1 and CAL2).

58. Oxygen Content Of Cal Gas 1 Enter value of Cal Gas 1 (to one decimal point).

Range:

0.1 to 20.9 % oxygen. Default setting is 8.0 % oxygen.

59. Maximum Acceptable Positive Error Gas 1 Set the maximum positive error above which the ‘Gas 1 Cal Error’ alarm will be initiated after the timed period set in

set-up step 55.

Range:

0.1 to 3.0 % oxygen. The default setting is 0.5 % oxygen.

60. Maximum Acceptable Negative Error Gas 1 Set the maximum negative error below which the ‘Gas 1 Cal Error’ alarm will be initiated after the timed period set in

set-up step 55.

Range:

0.1 to 3.0 % oxygen. The default setting is 0.2 % oxygen.

August 2007


61. Period Between Gas 1 Autocals Set the number of hours between autocal Gas 1. A typical time would be 24 or 168 hours. (Daily of weekly).

Range: 1 to 1999 hours. The default setting is 1 hour.

62. Duration Of Autocal Gas 1 Set the number of seconds that the autocal gas solenoid will be open. At the end of this period, if the oxygen level

measured is not within the limits set for Cal Gas 2, an ‘Gas 2 Cal Error’ will initiate. To determine the minimum time

required for a particular length or design of probe to settle, manually admit cal gas while observing the oxygen reading

in ‘RUN’ mode. Typical minimum times vary from 15 seconds to 90 seconds, depending on the probe length and gas

plumbing arrangement. If there is a filter fitted to the oxygen probe, the calibration check reading will be much closer

to the actual gas value.

Range:

0 to 90 seconds. The default setting is 10 seconds.

63. Freeze Time Gas 1 After the Cal Gas 1 period, the transmitter output will remain fixed (frozen) for an adjustable period to allow the probe

reading to return to the correct process level and avoid output ‘bumps’. The freeze period time required will depend on

the probe response time, and whether or not it has a filter fitted.

Range:

0 to 100 seconds in one second steps. The default setting is 30 seconds. To determine the required freeze time,

manually perform a calibration check with Gas 1 while the plant is in operation and note the time required for the

reading to return to the correct process level within approximately 0.5 % oxygen.

If the freeze time is set to zero the 4-20mA outputs will be updated during the purge time AND the freeze time. (ie. the

outputs will NOT be frozen) This mode will satisfy Environmental Protection Authorities if required.

64 to 69. Cal Gas 2 Parameters Enter the same requirements for Cal Gas 2 as per set-up steps 58 to 63 for Cal Gas 1. Cal Gas 2 could typically be 2 %

oxygen in nitrogen.

70. Process Alarm Enable If process alarms are not required, ‘NO’ can be selected. There will not be any process related alarms generated, and all

process alarms will be cancelled, if ‘NO’ is selected.

The process alarms are High oxygen, Low oxygen, Oxygen deviation, and Very low oxygen.

Options:

Yes

No *

71. High Oxygen Alarm Set the operating point for the high oxygen alarm relay.

Range:

0.1 –30.0% oxygen. The default setting is 10.0 % oxygen.

72. High Oxygen Delay Typically set at 30 seconds. This delay is to avoid nuisance alarms when the burner is undergoing transitions in firing

rate that can cause it to deviate from the oxygen set point, but recover quickly.

Range:

0–200 seconds. The default setting is 60 seconds.

73. Low Oxygen Alarm Set the operating point for the low oxygen alarm relay. Typically set at 2.0% oxygen, depending on the burner, it can be

used as a safety warning.

August 2007


Range:

0.1 –21% oxygen. The default setting is 2.5 % oxygen.

74. Low Oxygen Delay Typically set at 30 seconds. This delay is to avoid nuisance alarms when the burner is undergoing transitions in firing

rate that can cause it to deviate from the oxygen set point, but recover quickly.

Range:


75. Oxygen Deviation Alarm (Only available if ‘2 sensors’ is selected in set-up 1)

If the difference between 2 sensors running on a transmitter is greater than the limit set here, the alarm will be triggered.

This alarm could be used to give an on-line warning of a problem in one of the sensors.

Range:

0.1 –21% oxygen. The default setting is 2.0 % oxygen.

76. Oxygen Deviation Alarm Delay (Only available if ‘2 sensors’ is selected in set-up 1) A 30 second delay in the activation of this alarm will usually be ample to cover any deviation due to short-term

stratification differences between the two sensors.

Range:


77. Very Low Oxygen Alarm Set the operating point for the very low oxygen alarm relay, typically 0.5% oxygen. This limit can be used as a shut

down on a boiler as the normal operating level should never be this low.

Range:

0.001 –2.000% oxygen. The default setting is 0.500 % oxygen.

78. Very Low Oxygen Delay Set the very low oxygen alarm delay to the smallest possible period to avoid nuisance alarms/shut-downs, but still

maintain the fastest response to a fuel rich atmosphere

Range:


79. Alarm Relay #2 Any or all of the following alarm functions may be used to activate the alarm relay. They may be selected or de-selected

using the ‘ENTER’ buttons as in set-up step 33.

Options :

1. Low oxygen

2. High oxygen

3. Very low oxygen

4. Oxygen deviation between sensor 1 and sensor 2, (if sensor 2 is selected)

5. Gas 1 Check Error

6. Gas 2 Check Error

7. No Gas calibration (calibration not successful)

8. Probe or sensor under temperature

9. Calibration check in progress

10. Probe purge in progress

80. Alarm Relay #3 Alarm relay #3 has the same functions available as alarm relay #2. See SET-UP 79.

August 2007


81. Alarm Relay #4 Alarm relay #4 has the same functions available as alarm relay #2. See SET-UP 79.

In addition an alarm horn function is also available.

If ‘Horn’ is selected it will override any other selections. A relay selected as a ‘Horn’ driver will have the relay contacts

open circuit if there is an unaccepted alarm, and closed when a new alarm occurs.

82. Data To Print Any or all of the following values may be printed on a printer or computer connected to port 2. They may be selected or

de-selected using the ‘ENTER’ buttons as in set-up step 33. The log period follows in set-up step 83.

A sample of a printout is contained in Appendix 4.

NOTE: If a MODBUS™ address other than zero is selected in Set up 88, the data log function will be disabled.

For further details, see Set up 88.

RS232C protocol is :

Data word length Eight bits

Stop bits One

Parity None

Oxygen is always printed (average if 2 sensors are selected), plus any of the following

Options :

1. Sensor 1 oxygen

2. Sensor 2 oxygen

3. Sensor 1 EMF

4. Sensor 2 EMF

5. Sensor 1 temperature

6. Sensor 2 temperature, or Auxiliary temperature if 1 sensor is selected in Set up 1



9. Ambient temperature

10. Oxygen deficiency 1

11. Combustibles %, or oxygen deficiency 2 if 2 sensors are selected in set up 1.

12. CO2 theoretical maximum

13. Run hours since last service

14. Date of last service

83. Print Log Period Select the time interval between data print outs on the printer.

When the print period is selected below “1 minute”, the selection will automatically switch to “seconds”. The time can

then be selected up to 120 seconds. Above 120 seconds the time will switch automatically back to minutes.

NOTE: The print log could be up 2 seconds after the expected time.

Range:

5 to 120 seconds, 1 to 2000 minutes

84. Printer Baud Rate Select the correct BAUD rate for data to be transmitted out of the port to the printer.

Options:

300

1200

2400

4800

9600 *

August 2007


85. Reference Air Selection The reference air supply for the oxygen sensor is normally supplied from the transmitter. If the internal pump is not

being used, ‘External’ must be selected to stop the ‘Ref Pump Fail’ alarm. If an external air supply that has a known

relative humidity, select ‘Instrument Air’. This will allow the relative humidity level to be entered in set-up 86.

Less than half a litre per minute provides sufficient reference air for any sensor.

Note: The reference pump will only be turned on if either probe is over 550°C and the burner is enabled.

Options:

Int CM-15 *

Int MP-24 1.5v

Int MP-24 2.0v

Int MP-24 3.0v

External

Instrument air

86. Reference Air Relative Humidity This selection will only appear if ‘Instrument Air’ is selected in set-up 85.

If the reference air is being supplied from an instrument air supply, the relative humidity will be different from the

ambient air being measured within the transmitter. In this case set the set the RH to the RH of the air supply. As a

guide, the RH of a compressor driven air supply is about 10%.

Range:

1-100%

87. Damping Factor Each time a new reading is read from the oxygen probe or sensor, the new reading is averaged with the last readings

taken, before the new average is either displayed on the LCD, or sent to the 4 to 20 mA output. The number of readings

that are averaged together is adjustable with this function. A value of five for example, means that the new reading from

the probe or sensor and the previous four readings are averaged together before being displayed. A value of one entered

here will mean that every new reading from the probe or sensor will be sent to the display unaltered.

The smoothing of the oxygen signal is an exponential function. If a factor of 5 is used, a step change of input signal will

take about 5 seconds to reach 63% of the change on the output/display.

Range

1 to 20. Default setting is 5.

88. MODBUS™ Address This function is used when networking of one or more transmitters back to a master computer or data acquisition system

is required. For more details on the functions of the MODBUS™ see Section 2.12, and Appendix 6.

The valid range of MODBUS™ addresses is from 1 to 31. Any transmitter with zero selected as the MODBUS™

address will have the MODBUS™ disabled, and the data log function enabled.

For the connection details, see Section 3.15.

NOTE: If the MODBUS™ address is changed, the transmitter must be turned off and back on for the address change to

take effect.

Range:

0-31 Default setting is 0.

Extended Menus

89. Reference Air Pump Cycle The reference air pump will normally run all the time. However, if the inside case temperature is greater than 35°C the

pump will turn off for 30 seconds every minute to reduce the case temperature and extend the life of the pump.

Where the ambient temperature is always greater than 35°C, the life of the pump can be further extended by reducing the

pump on time. This function allows the user to set the on time of the pump over a 10 minute cycle.

Range:

1-10 Default setting is 10 (Always on)

Temperature >35°C Burst (Always on unless case >35°C) *

August 2007


90. Low Oxygen Calibration Factor, Sensor #1 The Novatech Controls zirconia oxygen sensors only require the sensor offset to be set. This corrects the oxygen

reading for any sensor offset at the 20.9% level (See Set-up 11 &12 for details). After setting the offset oxygen

readings other than 20.9% will also be within the rated specification for nearly all applications.

To allow zirconia probes made by other manufacturers to also be used on the Novatech Controls transmitter, a

correction factor can be entered to allow for oxygen reading much smaller and much larger than 20.9% to be fine tuned.

For complete details of how to set the “Low Oxygen Calibration” see Section 2.9.

Range

90 to 110. Default setting is 100.

91. Low Oxygen Calibration Factor, Sensor #2 Follow the same procedure outlined in set-up 90 for calibration of sensor #2.

92. Gas Calibration / Checking The Novatech oxygen sensor is an extremely stable sensor. However if it is required to make a fine adjustment to the

sensor offset voltage or the scaling at a specific oxygen concentration, this can be done using this function.

If Check is selected, the set-up steps 53 to 69 operate as described on the previous pages.

During the automatic gas calibration a mid gas calibration factor is saved in the next function, set-up 93 (and 94).

If Calibrate is selected, there will be addition options in set-up #53 and 57.

Options:

Calibrate

Check *

93. Oxygen Mid Point Calibration factor 1 During the automatic gas calibration described in set-up 92, a mid gas calibration factor is calculated and saved in this

function for probe #1. This factor is limited to less that 0.5% oxygen if the calibration gas (set in set-up 58 and 64) is

above 2.0% or 0.2% if the calibration gas is below 2.0% oxygen.

Range

-0.5 to +0.5% oxygen. Default setting is 0.0%.

94. Oxygen Mid Point Calibration factor 2 This factor is used in the same way Mid Point Calibration Factor #1 but is used for probe #2 if it is fitted.

95. Enable 4-20 Limit The zirconia oxygen sensor will not give a valid reading when it is below 650°C. So that an invalid sensor signal is not

used when the sensor is below 650°C the output 4-20mA channels are taken to 0mA.

If the output channels are required to reflect the oxygen reading even if the sensor is below 650°C, this option should be

set to NO.

Options:

Yes *

No

96. SSR Fail Alarm loops The 1632 transmitter monitors the solid state relays that are used to control the heater in the probe. If the SSR fails the

probe temperature will loops between 680°C and 800°C. When these variations are detected, the transmitter raise a

“SSR Fail” alarm and turn of the heaters when the number of loops exceeds the number set in this function.

A faulty SSR may be bypassed by using the SSR for the second probe or the gas solenoids if these is not being used.

See set-up 99 for more information.

Range

0 (Disabled) to 9. Default setting is 3.

August 2007


97. Heater SSRs swapping If a faulty SSR is detected with the “SSR Fail” alarm this function can be used to swap the SSR’s to get the transmitter

working.

“Swap SSR 1<–>2” will swap the two heater SSR’s. Use this option if the SSR on heater #1 fails and there is no probe

connected to heater #2. The heater for probe #1 will have to be plugged into the Heater #2 socket after this is changed.

“Swap Cal SSRs” will swap the two heater SSR’s for the two cal gas solenoid SSR’s. Use this option if the transmitter

is being used to control two probes but the calibration gas solenoids are not being used.

Options:

Normal *

Swap SSR 1<–>2

Swap Cal SSRs

August 2007


August 2007


MAINTENANCE

6

SECTION

NUMBER

TRANSMITTER MAINTENANCE

6.1 COLD START

6.2 A/D CALIBRATION

6.3 D/A CALIBRATION

6.4 PUMP REPLACEMENT

6.5 BACK-UP BATTERY REPLACEMENT

6.6 ELECTRONIC REPAIRS

PROBE MAINTENANCE

6.7 INSTALLING A NEW PROBE OR SENSOR

6.9 TEST EQUIPMENT REQUIRED

6.10 TESTING A PROBE OR SENSOR

6.11 PROBE OR SENSOR THERMOCOUPLE

6.12 HEATER FAILURE

6.13 FILTER BLOCKAGE

August 2007


TRANSMITTER MAINTENANCE

6.1 COLD START A ‘COLD START’ will reset all ‘Set-up’ mode entries to their factory default values. ‘COLD START’ will show on the

display for a second prior to a microprocessor initialising sequence, which takes about seven seconds.

After a ‘COLD START’, it is necessary to set all new variables in the ‘SET-UP’ mode, including calibration voltages

and time and date.

To initiate a ‘COLD START’ - Turn the mains power off

Remove the ‘COLD START LINK’ (this is located on the door PCB, next to the keyboard lock switch, behind the

shield)

Turn the mains power on. The message “Cold Start......” will be displayed.

Leave the LINK off until the message “Replace c/s Link” is displayed. Replace the LINK.

The date and version number of the software will be displayed.

A ‘WARM START’, which is performed by applying power with the COLD START LINK in its place, will retain all

data previously entered in the Set-up mode.

Location of Calibration Test Points

The transmitter maintains its accuracy over a very long period by continuously checking itself against internal stabilised

references. The only calibration required is to set the actual values of these references into battery backed memory. The

transmitter will read these references every minute and update its zero and span correction factors. See Section 5.5.7 to

10.

These references should be checked every 12 months. An AUTOCAL of the analog output section should always be

performed if these references are altered. See Section 6.3.

6.3 D/A (4-20mA OUTPUT CHANNELS) CALIBRATION The calibration can either be done using the ‘Auto Cal’ or ‘Manual Cal’.

Auto Cal

The ‘Auto Cal’ mode is selected in set-up 13 (and 16 for channel 2).

The transmitter will automatically divert the output back to the input, measure the offset and span, and record the

calibration factors for each channel.

If either of the channels are selected to be calibrated manually, an ‘Auto Cal’ will not change the factors.

Manual Cal

6.2 A/D CALIBRATION

Ribbon Cable

Ribbon Cable

Reference voltage

Reference voltagetest points.

common point.

Door Shield

RE

F V

OL

TS

1630-1 PCB

1

C

4

3

2

40 Way

16 Way

August 2007


The ‘Manual Cal’ mode is selected in set-up 13 (and 16).

Set the 4mA calibration first and then the 20mA calibration.

1. Select ‘Set 4mA Trim’ in set-up 13 (or 16).

2. Return to RUN mode.

3. Measure the output on the channel to be calibrated with a digital multimeter. If the current is not exactly 4.00mA,

return to set-up mode and change the 4mA calibration factor in set-up 14 (or 17).

4. Re-measure the current while back in RUN mode until the current is within 3.9 to 4.1mA.

5. Return to set-up mode and select ‘Manual Cal’ in set-up 13 (or 16).

Set the 20mA calibration factor.

6. Select ‘Set 20mA Trim’ in set-up 13 (or 16).

7. Return to RUN mode.

8. Measure the output on the channel to be calibrated with a digital multimeter. If the current is not exactly 20.00mA,

return to set-up mode and change the 20mA calibration factor in set-up 15 (or 18).

9. Re-measure the current while back in RUN mode until the current is within 19.9 to 20.1mA.

10. Return to set-up mode and select ‘Manual Cal’ in set-up 13 (or 16).

This calibration is now saved in battery backed memory until

The factors are changed in the manual calibration

The transmitter is forced into a COLD-START (see section 6.1)

The calibration mode in set-up 13 (or 16) is changed to Auto Cal and an Auto Cal is initiated.

NOTE: The 4mA or the 20mA trim mode will only be held on the output channels for 30 minutes before automatically

returning to ‘Manual Cal’ mode in set-up 13 (or 16).

6.4 PUMP REPLACEMENT The reference air pump is mounted on the 1630-2 PCB in the base of the transmitter. The operation of the pump is

monitored by the transmitter and alarms will be shown if a fault occurs. (“Pump Fail” alarm)

To replace the pump, unplug all the field wiring terminals. ie. Probe connectors, power connector etc.

The nuts for the pump screws are captive into the PCB, enabling the pump to be removed WITHOUT removing the

PCB. The pump wires can be unplugged.

6.5 BACK-UP BATTERY REPLACEMENT The back-up battery is contained within the battery-like real time clock/memory module, plugged into socket M2. It is

rated for an average service life of greater than ten years. The module is not re-chargeable and should be replaced every

three years in a stored transmitter with power off or every eight years with transmitters that have had the power on. The

memory module must be purchased from Novatech Controls or an agent of Novatech Controls.

After replacing the battery, re-enter all set-up mode functions.

6.6 ELECTRONIC REPAIRS Electronic schematics are included in Appendix 5. A competent electronic technician could perform troubleshooting

with these schematics, aided by the transmitter self-diagnostic alarms. It is recommended that service be performed on a

changeover circuit board basis. A fast turn-around or replacement service is available from Novatech or accredited

service agents. Other service aids, including a test EPROM firmware package and probe input simulator are also

available.

There are 3 fuses on the 1630-2 (terminal) PCB. FS1 and FS2 are M205 3Amp (or 3.15Amp) fast blow and are in the

input power active and neutral lines. FS3 is a PCB mounted 375mA fuse and is in series with the power transformer

primary winding.

If any of these fuses are blown the transmitter display will be blank.

6.7 INSTALLING A NEW PROBE OR SENSOR Whenever a new oxygen probe or sensor is installed, the millivolt offset value should be entered. To achieve this refer

to set-up 11 (and 12 for the second sensor).

August 2007


The probe or sensor offset is noted on a tag or label attached to probe or sensor. To check an offset on site, the probe or

sensor must be sensing air with reference air connected and allowed to settle at the operating temperature for 30

minutes. Read the offset in ‘RUN’ mode in millivolts on the lower line. Offset errors can occur if the sensor does not

have some air passing over it. A gentle flow of air in the calibration check port can be provided by a reference air pump

or similar. If a probe is in a process with the process running, the air purge on the sensing side of the oxygen sensor will

only be successful if the probe has a filter or small sensing hole. Probes with open sensing ends or with large sensing

holes allow the process gas to mix with the calibration gas, giving a false reading.

For heated probes or sensors, if the combustion appliance is not operational and the probe or sensor heater is interlocked

with the ‘FUEL ON’ signal, the ‘BURNER BYPASS’ switch should be set to ‘BYPASS’ to power the probe or sensor

heater after removing the probe or sensor from the flue. For unheated probes, the sensing tip must be raised to at least

650°C (1200°F) with a portable furnace.

CAUTION DANGER

Return the ‘BURNER BYPASS’ switch to normal (off) before installing the probe or sensor in the

flue.

6.8 TEST EQUIPMENT REQUIRED All measurements are simplified if a transmitter is connected to the probe or sensor. Readings can then be easily taken

of probe or sensor impedance, EMF, temperature and percent oxygen. The transmitter also provides proper heater

control for heated probes or sensors.

The following tests are described using readily available workshop equipment where a transmitter is not available. If a

transmitter is available the same test procedures will apply. First check all alarms on the transmitter, allowing time for

the probe or sensor to heat up after switch on.

An instrument to measure probe or sensor EMF and temperature is required. A 3 1/2 or 4 1/2 digit multimeter will

perform both measurements.

A separate temperature indicator to suit the probe or sensor thermocouple type is also useful, although not necessary.

A reference air pump is required and a cylinder of calibration check gas e.g. 2 % oxygen in nitrogen. The cylinder

should have a pressure and flow regulator. Both of these are inexpensive devices available from gas supply companies.

The calibration check gas should be chromatograph tested to an accuracy of 0.1 % oxygen.

TEST EQUIPMENT FOR UNHEATED PROBES

A small test furnace capable of raising the probe tip temperature to over 700°C (1300°F) is required. The furnace

should have a uniform temperature for about 50 mm (2”) either side of the sensor tip.

TEST EQUIPMENT FOR HEATED PROBES OR SENSORS

If a 1632 transmitter is available at the test location then no other equipment will be required. If not, then a controllable

power source for the heater is required. A Variac (variable transformer), set to approximately 80 volts will regulate the

probe or sensor temperature to over 700°C (1300°F).

6.9 TESTING A PROBE OR SENSOR With the probe or sensor heated to over 700°C (1300°F), either from a small test furnace or its own internal heater,

connect a digital multimeter to the probe or sensor electrode conductors. Connect the multimeter positive to the internal

electrode conductor. Connect reference air to and apply a gentle purge of air to the probe calibration check port.

Reference airflow should be 50 to 500 cc/minute (6 to 60 scfm). The multimeter should read zero millivolts + two

millivolts. If not, then there is a problem with the probe electrodes and the sensor needs refurbishing. Normally a faulty

probe electrode is indicated with a high source impedance. 1234 sensors do not require reference air but a gentle flow

of air should be admitted into the sample connection.

August 2007


To test the source impedance, set the multimeter to read ohms and take a measurement, within a couple of seconds, of

the probe or sensor impendence. Reverse the multimeter and repeat the reading. Take the average of the two readings

for an approximate measurement of impedance. If the impedance is above 10kΩ, then the probe or sensor needs to be

replaced. The probe or sensor must be over 700°C (1300°F) or above for this measurement. The reason that impedance

measurements need to be performed quickly, is that the zirconia sensor polarises with the DC voltage from the

multimeter across it.

If the probe or sensor tests reveal less than 2 mV offset and a good impedance reading, the next step is to apply a

calibration check gas. The calibration check gas should be inserted in the calibration check port. With the calibration

check gas flowing, the probe or sensor should develop an EMF according to the tables in Appendix 2. If the EMF

reading is low then there may be insufficient calibration check gas flow. Increase the calibration check gas until the

reading is correct. An excessive calibration check gas flow will cause cooling on one surface of the sensor, giving

temperature differential errors on the sensor.

As an alternative, using the reference air port, the calibration check gas can be inserted into the inside of a probe sensor.

This requires a lower flow rate, and thus lower usage of calibration check gas. The flow rate should be similar to that of

the reference air, which should be removed for internal calibration check. The probe or sensor EMF reading will be

identical but negative in polarity. A small flow of air should be flowing over the outside of the sensor, when testing in

this way.

Occasionally, a sensor can develop offset with a polluted electrode caused by contaminants in the flue gas stream. In

this case the impedance may be OK but the output incorrect. This phenomenon is rare.

6.10 PROBE OR SENSOR THERMOCOUPLE Although some unheated probes are specified without a thermocouple, most probes, both heated and unheated, have an

integral thermocouple which is fitted in to the four bore insulator. The transmitter has an alarm function that will advise

the operator of an open circuit thermocouple, however bench testing can be performed by simply measuring the

thermocouple continuity.

6.11 HEATER FAILURE For heated probe or sensors, a heater failure will cause a ‘SENSOR UNDER TEMP’ or ‘HEATER FAIL’ alarm.

Heaters can be tested with a continuity test. The heater impedance should be approximately 100Ω. Should the heater be

open or short-circuited, replace the probe or sensor.

6.12 FILTER BLOCKAGE For oxygen probes with filters in installations with entrained solids in the flue gas, it is sometimes necessary to replace

the filter. Filters are normally cleared with back purging. However fine fly ash or other particles can ultimately

completely block a filter necessitating filter replacement. A new probe filter can be fitted

August 2007


August 2007


APPENDICES

1. CONSTITUENT VALUES FOR VARIOUS FUELS

2. PROBE OR SENSOR EMF TABLES

3. % OXYGEN SCALE TO LOGARITHMIC

4. SAMPLE LOG PRINT OUT

5. CIRCUIT SCHEMATICS

6. MODBUS™ REGISTER MAP & APPLICATION NOTES

August 2007


August 2007


APPENDIX 1

CONSTITUENT VALUES FOR FUELS

If the transmitter is set up to have readout or output of combustibles or maximum carbon dioxide, then the fuel

constituents must be entered. Any or all of the variables can be modified and entered in set-up steps 39 to 45 and 46 to

51. (Refer to Section 5.5). Your fuel supplier or chemist should be able to give you all these values.

A is the heat of combustion of the fuel per gram atom of contained carbon.

H is the H/C atom ratio in the fuel.

O is the O/C atom ratio in the fuel.

N is the N/C atom ratio in the fuel.

S is the S/C atom ratio in the fuel.

M is the ratio of H2O molecules to C atoms in the fuel

August 2007


FUEL A H O N S M

_____________________________________________________________________________

Blast furnace gas 50.55 0.08 1.30 3.08 b a

Coke oven gas 256.88 5.60 0.25 0.23 b a

Producer gas 101.98 1.18 1.02 2.90 b a

Natural gas 209.90 3.86 0 0.10 0 0

Propane, natural 176.40 2.69 0 0 0 0

Butane, refinery 166.10 2.34 0 0 0 0

Methanol 172.59 3.97 1.00 — — —

Gasoline, motor 157.58 2.01 0 0 0 0

No 1 Distillate oil 149.65 1.83 0 — 0 —

No 2 Distillate oil 145.18 1.71 — — 0 —

No 4 Fuel oil 145.54 1.60 — — 0.01 0

No 5 Residual oil 142.25 1.44 — 0 0 0

No 6 Residual oil 136.52 1.25 0.01 0 0 0

Wood, non-resinous 110.91 2.26 1.07 0 0 c

Coal, bituminous 116.88 0.74 0.05 0 0 0.03

Coal, anthracite 104.98 0.35 0.05 0 0.01 0.04

Coke 99.63 0.11 0.01 0.01 0 0.01

a. The moisture level varies depending on the process details.

The calculated values assume M = O.

b. The sulphur level varies depending on the process details.

The calculated values assume S = O.

c. Variable.

Values calculated from the North American Combustion Handbook, Tables 2.1a and 2.1b.

August 2007


APPENDIX 2

PROBE OR SENSOR EMF TABLES

August 2007


ZIRCONIA OXYGEN SENSOR OUTPUT (mV)

PROBE TYPE 1231, SENSOR TYPE 1234

% OXYGEN mV at 720°C (1320°F)

___________________________________________________

21.0 0.00

20.5 0.46

20.0 0.99

19.5 1.53

19.0 2.09

18.5 2.66

18.0 3.25

17.5 3.85

17.0 4.47

16.5 5.11

16.0 5.77

15.5 6.45

15.0 7.15

14.5 7.87

14.0 8.62

13.5 9.40

13.0 10.21

12.5 11.05

12.0 11.92

11.5 12.83

11.0 13.78

10.5 14.78

10.0 15.82

9.5 16.92

9.0 18.08

8.5 19.30

8.0 20.60

7.5 21.98

7.0 23.45

6.5 25.04

6.0 26.75

5.5 28.61

5.0 30.65

4.5 32.90

4.0 35.42

3.5 38.28

3.0 41.58

2.5 45.48

2.0 50.25

1.5 56.41

1.0 65.08

0.5 79.91

0.2 99.51

_________________________________

'K’ TC mV 29.212 at 720°°°°C (1320°F)

These tables are based on the Nernst equation:

Sensor e.m.f. = 0.02154 x T x 1n x 20.95 / % oxygen, where T = ° K (° C + 273), e.m.f. is in mV’s

August 2007


ZIRCONIA OXYGEN PROBE OUTPUT (mV)

PROBE TYPE 1232 TEMPERATURE (ºC (°F))

% O2 600 700 800 900 1000 1100 1200 1300 1400

(1110) (1290) (1470) (1650) (1830) (2010) (2190) 2370) (2550)

_________________________________________________________________ _

20 0.917 1.023 1.128 1.233 1.338 1.443 1.548 1.653 1.758

19.5 1.394 1.553 1.713 1.872 2.032 2.192 2.351 2.511 2.671

19 1.882 2.098 2.313 2.529 2.744 2.960 3.175 3.391 3.607

18.5 2.383 2.657 2.930 3.203 3.476 3.749 4.022 4.295 4.568

18 2.899 3.231 3.563 3.895 4.227 4.559 4.891 5.223 5.555

17.5 3.428 3.821 4.214 4.607 4.999 5.392 5.795 6.177 6.570

17 3.974 4.429 4.884 5.339 5.794 6.249 6.705 7.160 7.615

16.5 4.535 5.054 5.574 6.093 6.613 7.132 7.652 8.171 8.691

16 5.114 5.699 6.285 6.871 7.457 8.042 8.628 9.214 9.800

15.5 5.711 6.365 7.019 7.673 8.327 8.981 9.635 10.289 10.944

15 6.327 7.052 7.777 8.501 9.226 9.951 10.676 11.400 12.125

14.5 6.965 7.762 8.560 9.358 10.156 10.954 11.751 12.549 13.347

14 7.625 8.498 9.371 10.245 11.118 11.991 12.865 13.738 14.612

13.5 8.308 9.260 10.212 11.164 12.115 13.067 14.019 14.970 15.922

13 9.018 10.051 11.084 12.117 13.150 14.183 15.216 16.249 17.282

12.5 9.756 10.873 11.991 13.108 14.226 15.343 16.461 17.578 18.695

12 10.523 11.729 12.934 14.139 15.345 16.550 17.756 18.961 20.167

11.5 11.324 12.621 13.918 15.215 16.512 17.809 19.106 20.403 21.700

11 12.159 13.552 14.945 16.338 17.731 19.124 20.516 21.909 23.302

10.5 13.034 14.527 16.020 17.513 19.006 20.499 21.992 23.486 24.979

10 13.952 15.550 17.148 18.746 20.344 21.942 23.540 25.139 26.737

9.5 14.916 16.625 18.333 20.042 21.751 23.459 25.168 26.877 28.585

9 15.933 17.758 19.583 21.408 23.233 25.058 26.883 28.709 30.534

8.5 17.008 18.956 20.904 22.852 24.801 26.749 28.697 30.645 32.593

8 18.148 20.227 22.305 24.384 26.463 28.542 30.620 32.669 34.778

7.5 19.361 21.579 23.797 26.015 28.223 30.450 32.668 34.886 37.104

7 20.659 23.025 25.392 27.758 30.124 32.491 34.857 37.224 39.590

6.5 22.052 24.578 27.104 29.630 32.156 34.683 37.209 39.735 42.261

6 23.557 26.256 28.954 31.653 34.351 37.050 39.748 42.447 45.145

5.5 25.194 28.080 30.965 33.851 36.737 39.623 42.509 45.395 48.281

5 26.986 30.077 33.168 36.259 39.351 42.442 45.533 48.624 51.715

4.5 28.967 32.285 35.603 38.922 42.240 45.558 48.876 52.194 55.512

4 31.182 34.754 38.326 41.897 45.469 49.041 52.613 56.185 59.757

3.5 33.693 37.552 41.412 45.271 49.131 52.990 56.850 60.709 64.569

3 36.592 40.783 44.975 49.166 53.358 57.549 61.741 65.932 70.124

2.5 40.020 44.604 49.189 53.773 58.357 62.941 67.525 72.110 76.694

2 44.216 49.281 54.346 59.411 64.476 69.541 74.605 79.670 84.735

1.5 49.626 55.310 60.995 66.680 72.364 78.049 83.733 89.418 95.102

1 57.250 63.808 70.366 76.924 83.482 90.040 96.598 103.156 109.714

0.5 70.285 78.336 86.387 94.438 102.488 110.539 118.590 126.641 134.692

0.2 87.515 97.540 107.564 117.589 127.614 137.638 147.663 157.687 167.712

TC mV

‘R’ 5.582 6.741 7.949 9.203 10.503 11.846 13.224 14.624 16.035

‘K’ 24.902 29.128 33.277 37.325 41.269 45.108 48.828 to to

‘N’ 20.609 24.526 28.456 32.370 36.248 40.076 43.836 47.502 to

These tables are based on the Nernst equation:

Probe e.m.f. = 0.02154 x T x 1n x 21/% oxygen

Where T = ° K (° C + 273)

August 2007


August 2007


APPENDIX 3

% OXYGEN SCALE to LOGARITHMIC

% OXYGEN % FULL SCALE

0.1 0

0.15 7.66

0.2 13.1

0.3 20.7

0.4 26.2

0.6 33.8

0.8 39.2

1 43.5

1.5 51.1

2 56.5

3 64.2

4 69.6

6 77.3

8 82.7

10 86.9

12 90.8

14 93.3

16 95.8

18 98

20 100

August 2007


August 2007


APPENDIX 4

SAMPLE LOG PRINT OUT

Novatech Controls 14-07-2005 06:14:00

Oxygen % 1.86

EMF 1 mV 38.0

Probe Temp 458C (856F)

Ambient T 21.9C (71.42F)

Servc'd 13/07/05

Humidity 43%

Sensor 1 Imp 5.7K

Next Purge at 06:00:00 17-07-2005

Next Print at 06:34:00 14-07-2005

06:00:11 14-07-2005 Heater 1 Fail Is Active

06:00:13 14-07-2005 O2% Low Is Active

02:33:17 14-07-2005 RefPump Fail Accepted

August 2007


August 2007


APPENDIX 5

CIRCUIT SCHEMATICS

August 2007


1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

D D

C C

B B

A A

Title

Number RevisionSize

A3

Date: 31/08/2007 Sheet ofFile: \\..\163x-1.prj Drawn By:

Block Diagram1 4

FHC

P5-[0..7]

L4-[3..6]

DAC-PS-[0..5]

P6-[0..7]

P4-[0..7]

D-A2

P3-2

/P6-1

Ser-[1..5]

SVcc

P3-0

VccGnd

Error

SVee

ADCADC.SCH

DAC-PS-[0..5]

P6-[0..7]

P3-[0..7]

/P6-1

Ser-[1..5]

SVcc

SVee

Vcc

Gnd

DACSDACS.SCH

L4-[3..6]

D-A2

P3-[0..7]

P4-[0..7]

P6-[0..7]

P5-[0..7]

P3-2

P3-0

VccGnd

Error

MICROMICRO.SCH

L4-[3..6]

P4-[0..7]

P5-[0..7]

P6-[0..7]

DAC-PS-[0..5] P3-[0..7]

Ser-[1

..5]

SV

cc

Vcc

P3-0

D-A2

P3-2

/P6-1

Gnd

Error

Svee

Novatech Controls

1630-1 1.6 B

Master diagram

SC1 SC2 SC3 SC4 SC5

Mounting holes

August 2007


1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

D D

C C

B B

A A

Title

Number RevisionSize

A3

Date: 31/08/2007 Sheet ofFile: \\..\Adc.sch Drawn By:

R5410k

R5310k

R52

10k

R56 10k

R511k

R701k8

R68 12K

R6382K5 1%

R69

270k

R71 1k

R671k5

AVcc

Gnd

C18 0.01uF

C190.01uF

AVee

Gnd

C15 0.01uF

X013

X114

X215

X312

X41

X55

X62

X74

INH6

A11

B10

C9

VEE7

X3

VCC16

GND8

IC32 CD4051 SMD

X013

X114

X215

X312

X41

X55

X62

X74

INH6

A11

B10

C9

VEE7

X3

VCC16

GND8

IC30

CD4051 SMD

Gnd

Gnd

Gnd

X013

X114

X215

X312

X41

X55

X62

X74

INH6

A11

B10

C9

VEE7

X3

VCC16

GND8

IC28

CD4051 SMD

X013

X114

X215

X312

X41

X55

X62

X74

INH6

A11

B10

C9

VEE7

X3

VCC16

GND8

IC31

CD4051 SMD

X013

X114

X215

X312

X41

X55

X62

X74

INH6

A11

B10

C9

VEE7

X3

VCC16

GND8

IC29

CD4051 SMD

AVee(5)

AVee(5)

AVee(5)

AVee(5)

AVcc(5)

AVcc(5)

AVcc(5)

AVcc(5)

89

IC18D

74HC04 SMD

P5-[0..7]

014

15

26

12 3

11 1

13

4 10

2

Vcc16

Gnd8

315

Vee90 1 2 3

/En7

IC2274HC4316 SMD

R104 100k

R103 100k

R102 1k

R101 1k

R100 1k

R99 1kR97 100k

R98 100kR96 1k

R95 1kR93 1kR91 1kR89 1k

C331.0/16VTant

C32

0.1

C31

0.1

C30 1.0/16V Tant

C29

0.1

C28

0.1

C27

0.1

C26

0.1

R94 1kR92 1kR90 1k

Gnd

R113

250R

1%

R111

1k5 1

%

R110

9k1 1

%

R108

4k7 1

%

R106

6k

8 1

%

R1052k2

Gnd

AVcc(5)

R606k8 R57

1k

R611kR5810k

AVcc(5)

AVee(5)

Gnd

L4-[3..6]

Gnd

GndAVcc

R88 1k

R86 1kR85 1kR84 1k

R83 1kR82

1kR801k

R78 1k

R871k

R77 1kR79 1kR81

1k

C25

0.1

C22

0.1

C21

0.1

C20

0.1

Gnd

Gnd

C24

0.1

Pro

be

anal

og

in

pu

ts

R45 100k R42

10kGnd

C10

10/16V TantGnd

Gnd

Gnd

Gnd

AVcc(5)

AVee(5)

Gnd

Gnd

AVee(5)

R591k

R66

12k

R65

47k

C16270p npo

Gnd

AVcc

AVee

Gnd

3

21

411

IC26AOPA4234UA

5

67

IC26BOPA4234UA

10

98

IC26C

OPA4234UA

12

1314

IC26DOPA4234UA

O2 sensor #1+

Probe TC +

Aux TC / Sen TC #2 -

CO2 i/p(1637) -

Rear head / RGC TC -

Burner f/b potTrim f/b pot

Heater interlock

+12v analog power

P5-4P5-3P5-2

P5-5

P5-4P5-3P5-2

P5-4P5-3P5-2

P5-4P5-3P5-2

DC volts pre-regulator50/60 mains freq

Heater drive enable

/P6(1) Clock

+5 Digital power

Rear head / RGC TC +

Analog ground

CJ Ambient sensor

R76

100k

AVee(5)

Cal 4-20mA signal

Channel #1 +p/sChannel #1 signalChannel #1 comChannel #2 signalChannel #2 +p/s

Channel #2 com

-12v Analog power

Ref air pump drive (DA-1)

+12v Analog power

Ref air pump current

P4-7

P4-1

R12

250RGnd

P4-3

1 2

714 IC34A

74HC14 SMD 3 4

IC34B

74HC14 SMD

014

15

26

12

3

11

1

13

4

10

2

Vcc

16

Gnd

8

315

Vee

90

12

3

/En

7

IC27

74HC4316 SMD

R75 10k

R74 2k2

R73 220k

R5510k

R62

10k

R50

10k

C23

0.1

C111uF non polar

C1210/16V Tant

R41RH sensor3

21

84

IC24A

OPA2132

5

67

IC24BOPA2132

Vcc

AVee(5)

Gnd

Gnd

GndAVee(5) Vcc

Gnd

Gnd

P5-0P5-1

L4-3

L4-4L4-5L4-6

P4-2DAC-PS-[0..5]

P6(4) Dig o/p data

P6(5) Dig o/p latchAnalog ComP6(6) Dig i/p data

P6(7) Dig i/p load/shiftDigital Com

/P6-1

P6-4

P6-5

P6-6

P6-7

P4-0

GndGnd

VccAVcc

AVee

Input MUX's, ADC and RH sensor2 4

FHC

L4-[3

..6]

P6-[0..7]

P4-[0..7]

D-A2

/P6-1

P6-[0..7]

DAC-PS-[0..5]

DAC-PS-0DAC-PS-1DAC-PS-2DAC-PS-3DAC-PS-4

DAC-PS-5

P3-2

P4-[0..7]

P5-[0

..7]

R1071k

Gnd

C3410/16V Tant

12345678910111213141516171819202122232425262728293031323334353637383940

CN4

40 PIN box header

RS-485 + (Ser4)RS-485 - (Ser3)

RS-232 Tx (Ser2)RS-232 Rx (Ser1)Serial common (Ser5)Watchdog relay drive

CO2 i/p (1637) +

Ser-[1..5]

Ser-1Ser-2Ser-4Ser-3

Ser-5

P4-6

Error

Ext Ref Air Flow Sens

Ser-[1..5]

1213

IC34F74HC14 SMD

Vcc

R64

100k

2.5v

SVcc

SVee

SVcc

SVee

I

C

O

IC3678L05

I

C

O

IC3579L05

C380.1

C370.1

C391.0/16V Tant

Gnd

R7212K

Gnd

+ i/p14

Vo

13

Com

p i

/p10

Vcc

12

- i/p1

Fout7

Com11

Cap

5

Vee

4

IC23VFC-32

Gnd

C14.001uF

+12v Serial coms power

-12v Serial coms power

O2 sensor #1-

Probe TC -Aux TC / Sen TC #2 +

C13 0.1

Gnd

C35 0.1

Gnd

P3-0

Avcc(5)

Avee(5)

AVcc

AVee

Gnd

Vcc

Gnd

Vcc5 6

IC34C74HC14

Gnd

12345678910111213141516

CN5

16PIN

O2 sensor #2+O2 sensor #2-

CO2 signal + (1637)CO2 signal - (1637)

Serial latch o/p enable

C40

0.1

Error

C41

0.1

C42

0.1

C43

0.1

C44

0.1

C45

0.1

C46

0.1

C47

0.1

C48

0.1

Gnd

Gnd

GndC490.1

R115 1k

R116 1k

C50

0.1

C51

0.1

Gnd

Gnd

C520.1

C530.1

Gnd

Gnd

C540.1

Gnd

C55

0.1

Gnd

C56

0.1

C57

0.1Gnd

C58

0.1Gnd

C600.01uF

Gnd

C59

0.1

Gnd

Vcc

R1171k2

R1184k7

Gnd

48

IC33LM336M-2.5

D-A2

VccGnd

Novatech Controls

1630-1 1.6 B

ADC, op amps, MUX

August 2007


1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

D D

C C

B B

A A

Title

Number RevisionSize

A3

Date: 31/08/2007 Sheet ofFile: \\..\Dacs.sch Drawn By:

REFin6

Agn

d5

Vout7

Vdd

8

Din1

CLK2

/CS3

Dout4

IC1MAX538

R24K7

48

IC2LM336M-2.5

R111K

R101K

R91K

R29

220R

R24

22

0R

R23

220R

Vcc

DAC data

DAC cs

48

IC7LM336M-2.5

R510K

R46k8

R301K

R3

10K

C310/16V Tant

Gnd

PWM output

LED1

R1410k

R221K

R81k

R27

47k

R32

470R

R21

1k

R1310k

R19100k

R25

10k

R7

100R

5

67

IC8BLM1458

3

21

84

IC8ALM1458

SVcc(5)

SGnd

SGnd

SGnd

SVee

SVee

SVcc

SGnd

R28

2k2

RX

Tx

I

C

O

IC3LM340L-05

C20.1

C410/25V Tant

R36

470R

R351K

Vcc

Gnd

Gnd

SGnd

SGndSGnd

LED2

123

LK3

RS-485 RS-232

SVcc(5)

R2647k

SVcc(5)

Vcc

SGnd

RS-232 Rx

RS-232 Com

RS-232 TxNet +

Net -

SVcc(5)+12 Isolated

12345678910

CN1

CON-10

RS-232 RxRS-232 TxNetwork -Network +Serial port common

RS-485 Dir

DAC-PS-[0..5]

ClockP6-1

P3-3

P6-2

P6-3

/P6-1

P3-5

P3-7

P3-4

P6-[0..7]

R18

1kSVcc(5)

R11k

Novatech Controls

1630-1 1.6 B

3 4FHC

D-A converters, Serial port

P3-[0..7]

/P6-1

P3-[

0..

7]

P6-[

0..

7]

DAC-PS-0

DAC-PS-1

DAC-PS-2

DAC-PS-3

DAC-PS-4

DAC-PS-5

Ser-1Ser-2

Ser-3Ser-4

Ser-5

Ser-[1..5]Ser-[1..5]

Tx4

TXen3

/RXen2

Rx1

NET-7

NET+6

Vcc

8G

nd

5

IC5SP485CS

TR1BC817

Vcc

R20

27kSVcc

12

LK2

LINK-2

I

C

O

IC4LM340L-05

SGnd

C610/16V Tant

C510/25V TantC1

0.1

SGndSGnd

SVccSVcc(5)

REF6

Gnd

5Vout

7

Vcc

8

Din2

CLK1

/LOAD3

Dout4

IC37LTC1257

DA

C-P

S-[0

..5]

SVcc

SVeeSVee

SVcc

SVee

SGnd

1 2

714

IC6A74HC14

3 4

IC6B74HC14

5 6

IC6C74HC14 89

IC6D

74HC14

1011IC6E

74HC14

1213

IC6F

74HC14

1 2

IC10A74HC04

3 4

IC10B

74HC04

56

IC10C

74HC04

89

IC10D

74HC04

1011

IC10E74HC04

1213

IC10F74HC04

D1BAV99

1

3

4

5

6

OP4PC-400

1

3

4

5

6

OP7PC-400

1

3

4

5

6

OP6PC-400

1

3

4

56

OP5PC-400

SVcc(5)

SVcc(5)

Vcc

1

3

4

5

6

OP3PC-400

1

3

4

5

6

OP2PC-400

1

3

4

5

6

OP1PC-400

R119

470

Gnd

Vcc

Gnd

Vcc

August 2007


1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

D D

C C

B B

A A

Title

Number RevisionSize

A3

Date: 31/08/2007 Sheet ofFile: \\..\Micro.sch Drawn By:

1234

56

1112

8IC16

74HC30 SMD

5 6

IC18C

74HC04 SMD

1213

IC18F74HC04

12

IC18A

74HC04 SMD

8

910

IC15C

74HC02 SMD

12

3IC15A

74HC02 SMD

D03

Q02

D14

Q15

D27

Q26

D38

Q39

D413

Q412

D514

Q515

D617

Q616

D718

Q719

OE1

CLK11

IC20

74HC374 SMD

D03

Q02

D14

Q15

D27

Q26

D38

Q39

D413

Q412

D514

Q515

D617

Q616

D718

Q719

OE1

CLK11

IC14

74HC374 SMD

D03

Q02

D14

Q15

D27

Q26

D38

Q39

D413

Q412

D514

Q515

D617

Q616

D718

Q719

OE1

LE11

IC25

74HC373 SMD

LGnd1

Vcc2

V13

RSel4

R/W5

E6

LD07

LD18

LD29

LD310

LD411

LD512

LD613

LD714

LE

D+

16

LE

D-

15

Gnd30

Gnd31

Gnd32

Gnd33

LCD1LCD-LM16A21

A010

A19

A28

A37

A46

A55

A64

A73

A825

A924

A1021

A1123

A122

A1326

A1427

A151

/CS20

OE/VPP22

DO11

D112

D213

D315

D416

D517

D618

D719

IC12

27C512

A010

A19

A28

A37

A46

A55

A64

A73

A825

A924

A1021

A1123

A122

A1326

A141

/CS20

/OE22

DO11

DI12

D213

D315

D416

D517

D618

D719

R/W27

IC13

HM62256 WIDE SMD

D0D1D2D3D4D5D6D7

A14

B13

E15

Y012

Y111

Y210

Y39

IC17B

74HC139 SMD

A2

B3

E1

Y04

Y15

Y26

Y37

IC17A

74HC139 SMD

A2

B3

E1

Y04

Y15

Y26

Y37

IC19A 74HC139 SMD

A14

B13

E15

Y012

Y111

Y210

Y39

IC19B 74HC139 SMD

R44 47K

Gnd

Gnd

VccGnd

SIP410K 9 PIN

Vcc

TR2BC817

R311K

D0D1D2D3D4D5D6D7

A14

A15

A14

A13

A12

A11A10A9A8

A7

A B

A6A5

A3A4

Gnd 45

6 IC15B

74HC02 SMD

2

Vcc

8 3

Vss

4

Clk7

Sw-in1

o/p6

IC21TC1232COA

R4910k

Vcc

Gnd

Rese

t

LCD-R/W

Gnd

Vcc

Latch 4

Latch 1

A0LCD-R/W

D0D1

D2

D3

D4

D5

D6

D7

D0D1

D2

D3

D4

D5

D6

D7

D0D1

D2

D3

D4

D5

D6

D7

D0D1D2D3D4D5D6D7

A0A1A2A3A4A5A6A7A8A9A10A11A12A13A14A15

R/WPH

Vcc

Vcc

Gnd

135791113151719

2468

101214161820

CN2

20 PIN (pin header)

D1D2D3D4D5D6D7A4A5

A2A3A1A0/PHR/WD0

Vcc

Gnd

SIP

147k

Vcc

PH

/PH

A0A1A2A3A4A5

A7A8A9A10A11A12A13A14A15

A6

A0A1A2A3A4A5

A7A8A9A10A11A12A13A14

A6

R/W

P3-0P3-1P3-2P3-3P3-4P3-5P3-6P3-7

P4-1

P4-3P4-4P4-5

P4-7

P5-0P5-1P5-2P5-3P5-4P5-5P5-6P5-7

P6-0P6-1P6-2P6-3P6-4P6-5P6-6P6-7

4 8

IC9LM336M-2.5

R162K2

Gnd

Vcc

R40

1M

XL1 10.0Mhz low profile

C96p8

C76p8

Gnd1 2 3

LK4

12

LK5

Cold start Link

1FF0

1FC0

1F

80-1

FF

F

TR4BC817

TR3BC817

R384k7

R374k7

Gnd

P5-6

L4-[3..6]

L4-3

L4-4

L4-5

L4-6P4-0

P4-2

P4-4

P3-1

P3-2

P3-6

Gnd

Vcc

+

M1DS1994Gnd

Microprocessor, display and keyboard4 4

FHC

/WR20

SYNC23

RESETout24

D-A167

D-A266

P3(0) EV13

P3(1) EV22

P3(2) EV379

P3(3) PWMout78

P3(4) RxD77

P3(5) TxD76

P3(6) Sclk75

P3(7) Srdy74

P4(0) AN065

P4(1) AN164

P4(2) AN263

P4(3) AN362

P4(4) AN461

P4(5) AN560

P4(6) AN659

P4(7) AN758

DA-Vref68

P5(0)11

P5(1)10

P5(2)9

P5(3)8

P5(4)7

P5(5)6

P5(6)5

P5(7)4

AD-Vref69

Xin28

Xout29

/RD21

/RESET26

P6(7)12

P6(6)13

P6(5)14

P6(4)15

P6(3)16

INT3 P6(2)17

D733

D634

D535

D436

D337

D238

D139

D040

PH31

R/W22

A1542

A1443

A1344

A1245

A1146

A1047

A948

A849

A750

A651

A552

A453

Vcc

72

CN

25

A-V

cc71

AV

ss70

Vss

32

Vss

73

INT2 P6(1)18

INT0 P6(0)19

A354

A255

A156

A057

IC11M37451S4FP SMD

L4-[

3..

6]

D-A2

P3-[0..7]

P4-[0..7]

P5-[0..7]

P6-[0..7]

P3-[0..7]

P4-[0..7]

P5-[0..7]

P6-[0..7]

SIP21k

12

LK12x1 pin link P

3-0

P6-0

P5-[0..7]P5-[0..7]

P3-2

R/W

PH

8 9

IC34D

74HC04

10 11

IC34E

74HC04

R1122M2

R114100K

C361.0/16V Tant

Gnd

Error

Power/reset LED

11

1213

IC15D

74HC02 SMD

123

LK6

3x1 pin link

A0

W/dog

A0

R109

1k

SW7SW9

SW3

SW8SW6

SW4SW2

Gnd

R391k

R43

1k

R46

1k

LED7

LED6

LED5

Gnd

LED8

Vcc

A[0..15]

LED4 LED3

R341k

R331k

Vcc

R48

1M

R471M

Gnd

Gnd

C8

10/16V Tant

Gnd

AlarmAutocal

Display

Purge

Setup mode

Cal check #2

Neutral

Cal check #1

R6

10kVcc

SIP

347K

Vcc D0D1D2D3

D4D5D6D7

A6

C17100p

Gnd

R174k7

Vcc

1011

IC18E

74HC04 SMD

34

IC18B

74HC04 SMD

SW5

P3-0

INC DEC

P4-5

SW1Gnd

Keyboard Lock

R15

10k

Vcc

Vcc

Vcc

1 2 3 4 5 6 7 8

CN3CON-PH3.8-8

Gnd Vcc

External Keypad/LED's

Alarm

Setup

Neutral

P4-6

Gnd

Gnd

Gnd

Error

Vcc

Gnd

D3BAV99

D2BAV99

Gnd

P5-7

Gnd

Vcc

C61

0.1

Gnd

C62

0.1Vcc

1 2

LK7

2x1 pin link

Gnd

D-A2

Novatech Controls

1630-1 1.6 B

Microprocessor

August 2007


1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

D D

C C

B B

A A

Title

Number RevisionSize

A3

Date: 31/08/2007 Sheet ofFile: \\..\163x-2.prj Drawn By:

Novatech Controls

1630-2

Terminal allocation, Block diagram1.5

1 4FHC

163x Analyser

Probe +Probe -Probe TC+Probe TC-TC2 / Aux +TC2 / Aux -

Output #1+

Output #2 +Output #2 -

Output #1 -

Purge flow swPurge flow swFuel 1/2

Com alarmCom alarm

Alarm relay #2Alarm relay #2

Purge solenoidPurge solenoidCal 1 solenoid

Cal 2 solenoid

Probe heater #1Probe heater #1

Mains ActiveMains Neutral

Mains Earth

Fuel 1/2

Cal 1 solenoidCal 2 solenoid

Burner on i/pBurner on i/p

+12v supply out

RGC I/P +RGC I/P -Sensor #2 +Sensor #2 -

Remote alarm resetRemote alarm reset

RS-232 RxRS-232 TxNetwork -Network +Serial port common

Alarm relay #3Alarm relay #3Alarm relay #4Alarm relay #4

T+

-

IC1LM35

TR4BC550

TR3 BC550

D3 1N4004Vcc

123456789

10111213141516171819202122232425262728293031323334353637383940

CN1

40 pin IDC crimp/solderR31

10k

R38

10k

R1510k

R7 10k

R5 10k

R6 10k

R1410k

R13

10k

Vcc

L5-[0..5]

L6-[0..7]

L2-[0..3]

P6-[0..7]

/P6-1

Senable-1

DIGITAL LATCHESDIGIO.SCH

OutputCh#1+OutputCh#1-OutputCh#2+OutputCh#2-

4-20CalSig+

Ch#1Sig

Ch#2Sig

L5-[0..5]

SerPS[1..3]

4-20CalSig-

4-20mA DRIVERS4-20DRV.SCH

4-20CalSig+

PreReg

50/60Hz

P6-7

P6-6

P6-4

/P6-1

P6-5

P4-6

Vcc

AGnd

AVcc

AVee

D1Vcc

D1Gnd

D2Vcc

D2Gnd

50/60HzHV[1..6]

Sol[1..4]

L2-[0..7]

HtrEn

L6-[0..7]

DA-2

P4-5

PreReg

SerPS[1..3]

Unreg

Error

POWER SUPPLYPOWER.SCH

L2-1

L2-6

L2-2

L2-[0..7]

L5-[0..5]

Sol1

Sol2

Sol3

HV4HV5

HV1HV2

Ref Air Flow Sensor

L2-4

P6-[0..7]

L6-[0..7]

Sol[1..4]

HV[1..6]

1234567

CN7

123456789

101112

CN6

12345

CN5

1234

CN4

12345678

CN3

123456

CN11

12

CN10

1234

CN12

TH1

135-102DAG-J01

RL2FBR-46D005P

RL6

RL1

RL5

OutputCh#1+OutputCh#1-OutputCh#2+OutputCh#2-

L5-0

L5-1

L5-2

L5-3

HtrEn

DA-2

PreReg

P4-5

50/60Hz

Ch#1Sig

Ch#2Sig

R31M

R10

1M

R111M

12

CN8CON-PH3.8-2

3738 AVcc

Sensor #2AVee

1234567

89

10111213141516171819

2021222324

25262728

2930313233343536

414243444546

5049

47

5152

Sol4

SerPS[1..3]

SerPS1

Ser

PS

2

SerPS3SVcc

SVee

D1 R1 10k

AGnd

R12 10M

4-20CalSig-

R910M

123456789

10111213141516

CN2

16 PIN IDC crimp/solder

123456789

10

CN14Unreg +12v+5vDig comDig comSignal +Signal -Analog comAnalog com+12v-12v

Unreg

Senable-1

Probe heater #2Probe heater #2

12

CN15

5354 HV6

C29

0.022uF/240V

C30

0.022uF/240V

Error

TR?

BC550

TR?

BC550

TR?

BC550

D? 1N4004

D? 1N4004

D? 1N4004

R? 10k

R? 10k

R? 10k

Vcc

Vcc

Vcc

123

CN?

12vSignalCommon

Burner Feedback Transducer

August 2007


1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

D D

C C

B B

A A

Title

Number RevisionSize

A3

Date: 31/08/2007 Sheet ofFile: \\..\4-20drv.sch Drawn By:

Novatech Controls

1630-2

4-20mA Output Drivers1.5

3 4FHC

163x Analyser

R19

100R

5

67

IC6B

LM358

R23220K

R20220K R26

220K

R39220K

LED23mm LED

R17

100R

5

67

IC5BLM358

R22 220K

R18 220K R25 220K

R32

1M

LED1

3mm LED

3

21

84

IC6A

LM358

3

21

84

IC5A

LM358

Ch#1 +12

Ch#1 -12

Ch#1 sig

Ch#1 com

D1Vcc

D1Gnd

D1Vee

Ch#2 +12Ch#2 Com

Ch#2 -12

Ch#2 sig

D2Vee

D2Vcc

D2Gnd

OutputCh#1+OutputCh#1-

OutputCh#2+OutputCh#2-

4-20CalSig+

Ch#1SigCh#2Sig

L5-4

L5-5

L5-[0..7]

RL4

FBR-46D005P

RL3

FBR-46D005P

TR2BD139

TR1BD139

L5-[0..7]

4-20CalSig+

OutputCh#1+OutputCh#1-OutputCh#2+

OutputCh#2-

Ch#2SigCh#1Sig R34

1M

R33 220K

D1Gnd

D2Gnd

R4

47R

C7

0.1uF

C60.1uF

4-20CalSig-4-20CalSig-

August 2007


1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

D D

C C

B B

A A

Title

Number RevisionSize

A3

Date: 31/08/2007 Sheet ofFile: \\..\Digio.sch Drawn By:

SE

R14

SR

CL

K11

SR

CL

R10

RC

LK

12

E13

O0

15

O1

1

O2

2

O3

3

O4

4

O5

5

O6

6

O7

7

Q7

9

IC2

74

HC

595

SE

R14

SR

CL

K11

SR

CL

R10

RC

LK

12

E13

O0

15

O1

1

O2

2

O3

3

O4

4

O5

5

O6

6

O7

7

Q7

9

IC7

74H

C595

Vcc

Vcc

SER10

P011

P112

P213

P314

P43

P54

P65

P76

CLK12

CLK215

PL1

Q79

Q77

IC374HC165

Digital output data

Clock

Digital output latch

Digital input data

Digital input load/shift

L5-0

L5-1

L5-2

L5-3

L5-4

L5-5

L6-0

L6-1

L5-[0..5]L6-[0..7]

L2-0L2-1

L2-3L2-4L2-5L2-6L2-7

L2-[0..7]

Remote furnace stop

Purge Flow Switch/ Rem burn out

Fuel 1 or 2 input

Burner Bypass SwitchBurner on Relay

Terminal PCB select

Remote Alarm Reset

Mains vlotage selector switch

P6-4

P6-5

P6-6

P6-[0..7]

SIP110k

Vcc

Notatech Controls

1630-2

Digital input/output1.5

2 4FHC

163x Analyser

P6-7

L6-2

L6-3

L2-2

/P6-1

L5-[0..5]L6-[0..7]

L2-[0..7]

P6-[

0..

7]

Latch #2

12LK2

LINK2X1

/P6-1

Ala

rm r

ela

y #

1A

larm

rela

y #

2A

larm

rela

y #

3A

larm

rela

y #

44-2

0 C

al

rela

y #

14-2

0 C

al

rela

y #

2In

c t

rim

rela

yD

ec t

rim

rela

y

Heate

r #1

Purg

e s

ole

noid

Gas

cal

sole

noid

#1

Gas

cal

sole

noid

#2

SIP

210K

Vcc C5

0.1uF

C20.1uF

C40.01uF

Latc

h #

5

Latc

h #

6

Senable-1

Heate

r #2

L6-4

R4510k

Vcc

Senable-1

L6-5

August 2007


1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

D D

C C

B B

A A

Title

Number RevisionSize

A3

Date: 31/08/2007 Sheet ofFile: \\..\Power.sch Drawn By:

Novatech Controls

1630-2

Power Supply, Reference air pump1.6

4 4FHC

BR3

W04 1A bridge rect

C14

2200uF

/25v R

B,

0.3

"

C13

470uF/16v

/En

5

Gnd

3

Vout2

Vin1

F/B4

IC12LM2575T-5.0, small heatsink

D4

SR104 Schotky diode

L1

PE 92114 330uH

C20

220uF/35vC9

1.0uF Tant

12v

+5v 330mA

-12v

C21

220uF/35vC110.1uF

BR2

W04 1A bridge rect

C26

220uF/35vC10

1.0uF Tant

C27

220uF/35v

C120.1uF

BR4

W04 1A bridge rect

C19

220uF/35vC15

1.0uF Tant

C25

220uF/35v

C170.1uF

BR1

W04 1A bridge rect

1

2

11

3

8

7

12

10

16

18

13

15

14

17

TF1

SD-926c

TR6

BC550R43

10k

R42 1k

50/60Hz

Out

Out3

In1

In2

FL1

PLAM 2321 R9FS1

FS2

Vcc

HV[1..6]

Sol[1..4]

Sol1

Sol2

Sol3

L2-[0..7]

L2-3

L2-4

HtrEn

L6-[0..7]

L6-1

L6-2

L6-3

+in1

-in2

-out3

com-out4

+out5

PS1

HPR-104 (5 to +/-12v)

TR5BD140

R27

1ohm

R24 12kR16 10k

3

21

84

IC4A

LM358

5

67

IC4BLM358 R29

150

DA-2

40 Ref air pump -39 Ref air pump +

R21

5k6

R281k

P4-6

163x Analyser

Mains E

L2-0

HV1

HV2

HV3

HV4

HV5

Heater com

Heater 1

Mains N

Mains A

Vcc

AVee

AGnd

AVcc

D1Vcc

D1Vee

D1Gnd

D2Vee

D2VccD2Gnd

-12v

+12vDAC 2 Com

PreReg

12v/300

15v/30

15v/30

15v/30

15

v/3

0

15v/50

15v/50

240v

110v

C8

10/35v Elect

R30 680

C310uF/16v RB

L6-0

C1

0.1uF

12

CN9

AA

KK

22

11

SSR4

S202-S02

AA

KK

22

11

SSR3

S202-S02

AA

KK

22

11

SSR2

S202-S02

AA

KK

22

11

SSR1

S202-S02

I

C

O

IC878L12

I

C

O

IC1079L12

I

C

O

IC978L12

I

C

O

IC1179L12

I

C

O

IC1378L12

I

C

O

IC1479L12

SW3

V202-12-MS-02-Q

RL7

SW1

R401k

LED3Burner on LED

Burner Bypass switch

SW2

POWER ON

LED4Heater #1 On

C22 0.022uF

C18 0.022uF

C16 0.022uF

HV

[1..

6]

Sol[

1..

4]

L6-[0

..7]

L2-[0

..7]

50/60Hz

PreReg

P4-6

DA-2

HtrEn

R37220R

R36

220R

R35

220R

R41220R

LED7

LED6

LED5

C280.022uF

Sol4

D5

1N4004

SerPS1

SerPS2

SerPS3

Ser

PS

[1..

3]

SerPS[1..3]

C24

0.022uF

C230.022uF

12345

CN13

AA

KK

22

11

SSR5

S202-S02

HV6

Heater 2

R44220R

L6-4

LED8Heater #2 On

0-2.5v

0-5v

Unreg

FS3

250mA axial lead fuse

Unreg

TR11BC560

R48

10k

R5010k

TR

10

BC

560

R4910k

R5110k

R47 10k

TR12BC550

Error

L6-5

Error

Vcc

R56 10k

C331.0uF

August 2007


August 2007


APPENDIX 6

MODBUS™ Register Map and Application Notes

MODBUS™ Functions Supported are:-

ReadHolding Register Function 3

WriteHolding Register Function 6 ( for allowable addresses only )

Introduction.

The 1632 transmitter implements the MODBUS™ slave protocol, it is intended to work in conjunction with a

MODBUS™ master.

This is accomplished by setting the MODBUS™ address to some non-zero value in the range 1-31, setting the jumper

positions to select the RS485 half duplex configuration, and re-starting the transmitter.

The master must be configured as follows.

Baud Rate 9600

Parity none

Stop Bits 1

RS485 Half Duplex

Mode RTU ( binary mode)

A typical transaction would be to read the current value of a variable from the transmitter.

The master send a ReadHoldingRegister packet, with the appropriate address and the transmitter responds with data at

that address.

The Register Addresses are as follows, to convert to Schneider addresses for earlier model PLC's address space, add

40001 to each address.

or for later model PLC's with linear address space the address co-responds directly to %MW XXXX address.

For Example, to read probe temperature set-point -

Read %MW1436 which is equivalent to holding register 41437 = 40001 + 1436

Some data is 32 bit data (double) which requires some care to ensure that the word order is correctly interpreted.

For Example, OXYGEN32, (dual probe) which is at address 2052 is interpreted as follows.

2052 contains the high 16 bits for probe 1 oxygen

2053 contains the low 16 bits for probe 1 oxygen

2054 contains the high 16 bits for probe 2 oxygen

2055 contains the low 16 bits for probe 2 oxygen

August 2007


Configuration and Setup Addresses

Holding

Reg. Function Description

716 Probe #1 offset 10 = 1.0mV

717 Probe #2 offset 10 = 1.0mV

Purge control related variables

754 Purge enable 0= off, 1= on

Calibration checking gas related variables

759 Gas calibration check 0= off, 1= 1 gas, 2= 2 gasses

2048 Probe #1 EMF 100,000 = 100.000 mV

2050 Probe #2 EMF 100,000 = 100.000 mV

2052 Probe #1 OXYGEN 100,000,000 = 100.0%

2054 Probe #2 OXYGEN 100,000,000 = 100.0%

2056 Probe #1, Impedance 1,000 = 1 k Ω

2058 Probe #2, Impedance 1,000 = 1 k Ω

2060 Probe #1 TC mV 100,000 = 100.000 mV

2062 Probe #2 TC mV 100,000 = 100.000 mV

2064 Probe #1 temperature 700 = 700 degC

2066 Probe #2 temperature 700 = 700 degC

2068 ALRM-ARRAY Array of current alarm status. See below

2084 ALRM-TIMES Array of timestamp of alarms

Alarm array order -

1. Heater 1 fail 2. Sensor1 fail (Impedance too high) 3. Probe 1 filter blocked 4. Probe 1 thermocouple open circuit 5. Reference air Pump fail 6. Battery backed RAM fail 7. Mains frequency measurement fail 8. ADC warning (outside normal specifications, but still accurate) 9. DAC warning (outside normal specifications, but still accurate) 10.Oxygen % low

11.Oxygen % high

12.Oxygen % very Low

13.Oxygen % deviation too high between oxygen probes

14.Oxygen % Deficient (oxygen % low on oxygen deficient range)

15.ADC Calibration fail

16.Gas 1 calibration error

17.Gas 2 calibration error

18.Burner bypass switch on

19.Aux thermocouple open circuit

20.Reference air pump fail

21.DAC Calibration fail

22.Probe Calibration

23.Heater 2 Fail

24.Sensor 2 Fail (Impedance too high)

25.Prbe2 thermocouple open circuit

26.Probe temperature below 650 °C

27.Gas calibration check in Progress

28.Probe Purging

29.Alarm horn

30.Probe Temperature high

August 2007


INDEX 1230 Oxygen probes 9

1231 Heated oxygen probe 9

1234 Oxygen sensor installing 24

4-20 mA calibration 48

Alarms

High oxygen 56

Low oxygen 56

Very low oxygen 57

Alarm button 39

Alarm relays 41

Alarm schedule 39

Alarms 29, 33

Common alarm 39

Selectable alarms 40

Summary 39

Analyser mounting 22

Analyser 17

Analyser description 6

Analyser system 6

Auxiliary temperature 19

backlight 41

Back-up battery 20

Battery 20

Battery replacement 65

Baud rate 58

Burner by-pass switch 41

Burner by-pass switch 33

Calender 47

Calibration

A/D 64

Checking of probes 19

Electronics 18

Probes 18

Sensor 33

Test points 64

Calibration

D/A 64

Calibration check connecting calibration solenoid 30

Calibration checking 90

Calibration gas check 34

Calibration gases 55

Centigrade 51

Cold start 64

Commissioning 33

Common Alarms 29

Damping Factor 59, 60

Damping factor 60, 61

Display button 38

Dual fuel 53

Dual fuel input connecting 31, 35

Dust in the flue gas 34

Fahrenheit 51

Filter Blockage 67

Filter purge pressure switch 14

Filter purging 34

Function select 46

Heater failure 67

Heater interlock relays 27

Impedance 17

Interlock 27

Lower Line 7

Lower line display functions 52

Model 1232 unheated oxygen probe 9

Model 1234 oxygen sensor 10

Number of sensors 47

Option or value 46

Outputs 7

Oxygen deviation oxygen deviation 57

Oxygen probe installing 22

Oxygen probe 12

Power 33

Power lamp 41

Pressure 17, 52, 53

Print log data 58

Printer connecting 31, 32

Probe testing 66

Probe cable 28

Pump replacement 65

Purge 19

Automatic 54

Connecting purge solenoid 30

Freeze time 55

Purge / Cal time 54

Range of Indication 7

Range of output 1 7

Range of output 2 7

Reference air connecting 31

Reference air selection 59

Reference voltage 47

Relative humidity 59

Repairs 65

RH 59

RS 232 19

RS 485 19

Run mode 33

Sensor type 49

Serial port 31, 32

Service date 49

Set-up & run modes 46

Set-up function details 47

Set-up mode 33

Set-Up Mode Functions 44

software 3

Specifications 5, 12

Stratification 34

Technical Enquires 3

Testing A Probe 66

Thermocouple type probe 49

Thermocouple type auxiluary 50

Time 47

Top line units 51

Transmitter 4-20 mA 50

August 2007


Version, software 3

Watchdog timer 20

Zirconia sensor 16

Zirconia sensor output 74

August 2007


Declaration of Conformity Application of Council Directives: 89/336/EEC (92/31/EEC) 72/23/EEC Standards to which conformity is declared: EN550011.1:1995 (ISM, Group 1, Class B) EN55014:1995 (Clause 4.2) EN50082-2 (Industrial) EN61010-1 AS61000.4.5:1999 IEC-68-2-2 IEC-68-2-3 AS1099.2.6

Manufacturer’s name: Novatech Controls Pty Ltd

Manufacturer’s address: 309 Reserve Road Cheltenham VIC 3192 AUSTRALIA Type of equipment: Oxygen Transmitter Equipment Class: ISM, Group 1, Class B

Model Number: 1630 Series Transmitter 1231 Oxygen Probe 1234 Oxygen Sensor

I hereby declare that the equipment specified herein conforms to the above

directive(s) and standards(s). Full Name: Fraser Chapman Position: R & D Manager

August 2007


Novatech Controls Pty. Ltd. ABN 57 006 331 700 Conditions of Sale

1. Interpretation In these conditions:

(a) `Seller' means Novatech Controls Pty. Ltd.

ABN 57 006 331 700 of 309 Reserve Road,

Cheltenham Victoria, 3192 which is the seller

of the goods.

(b) `Buyer' means the buyer of the goods specified

in the seller's quotation, or in the buyer's order

for the goods.

(c) `Goods' means the products and, if any,

services specified in Buyer's, orders or Seller's

order acknowledgments from time to time.

(d) Nothing in these conditions shall be read or

applied so as to exclude, restrict or modify or

have the effect of excluding, restricting or

modifying any condition, warranty, guarantee,

right or remedy implied by law (including the

Trade Practices Act 1974) and which by law

cannot be excluded, restricted or modified.

2. General These conditions (which shall only be waived in

writing signed by the seller) prevail over all

conditions of the buyer's order to the extent of any

inconsistency.

3. Terms of sale The goods and all other products sold by the seller

are sold on these terms and conditions.

4. Seller's quotations Unless previously withdrawn, seller's quotations are

open for acceptance within the period stated in them

or, when no period is so stated, within 60 days only

after its date. The seller reserves the right to refuse

any order based on this quotation within 7 days after

the receipt of the order.

5. Packing The cost of any special packing and packing

materials used in relation to the goods are at the

buyer's expense notwithstanding that such cost may

have been omitted from any quotation.

6. Shortage The buyer waives any claim for shortage of any

goods delivered if a claim in respect for short

delivery has not been lodged with seller within seven

(7) days from the date of receipt of goods by the

buyer.

7. Drawings, etc.

(a) All specifications, drawings, and particulars of

weights and dimensions submitted to the buyer

are approximate only and any deviation from

any of these things does not vitiate any contract

with the seller or form grounds for any claim

against the seller.

(b) Except as referred to in Clause 13.1 herein, the

descriptions, illustrations and performances

contained in catalogues, price lists and other

advertising matter do not form part of the

contract of sale of the goods or of the

description applied to the goods.

(c) Where specifications, drawings or other

particulars are supplied by the buyer, the

seller’s price is made on estimates of quantities

required. If there are any adjustments in

quantities above or below the quantities

estimated by seller and set out in a quotation,

then any such increase or decrease are to be

adjusted on a unit rate basis according to unit

prices set out in the quotation.

8. Performance Any performance figures given by the seller are

estimates only. The seller is under no liability for

damages for failure of the goods to attain such

figures unless specifically guaranteed in writing. Any

such written guarantees are subject to the recognised

tolerances applicable to such figures.

9. Acknowledgment regarding facilities for

repairs or parts The buyer acknowledges that the seller does not

promise or represent that facilities for the repair of

the goods, or that parts of the goods are or will be

available. The buyer must ensure that each purchaser

of the goods from the buyer receives notice that the

seller does not promise that facilities for the repair of

the goods will be available; or parts for the goods

will be available.

10. Delivery

(a) The delivery times made known to the buyer

are estimates only and the seller is not be liable

for late delivery or non-delivery.

(b) The seller is not be liable for any loss, damage

or delay occasioned to the buyer or its

customers arising from late or non-delivery or

late installation of the goods.

(c) The seller may at its option deliver the goods to

the buyer in any number of instalments unless

there is an agreement in writing between the

parties to the effect that the buyer will not take

delivery by instalments.

(d) If the seller delivers any of the goods by

instalments, and any one of those instalments is

defective for any reason:

(i) it is not a repudiation of the contract of

sale formed by these conditions; and

(ii) the defective instalment is a severable

breach that gives rise only to a claim for

compensation.

11. Passing of risk Risk in the goods passes to the buyer upon the earlier

of:

(a) actual or constructive delivery of the goods to

the buyer; or

(b) collection of the goods from the seller or any

bailee or agent of the seller by the buyer's agent,

carrier or courier.

12. Loss or damage in transit

(a) The seller is not responsible to the buyer or any

person claiming through the buyer for any loss

or damage to goods in transit caused by any

event of any kind by any person (whether or not

the seller is legally responsible for the person

who caused or contributed to that loss or

damage).

(b) The seller must provide the buyer with such

assistance as may be necessary to press claims

on carriers so long as the buyer:

(i) has notified the seller and the carriers in

writing immediately after loss or damage

is discovered on receipt of goods; and

(ii) lodges a claim for compensation on the

carrier within three (3) days of the date of

receipt of the goods.

13. Guarantee

13.1 The seller's liability for goods manufactured by

it is limited to making good any defects by

repairing the defects or at the seller's option by

replacement, within a period as specified in

Seller's catalogues or other product literature for

specified cases or not exceeding twelve (12)

calendar months after the goods have been

dispatched (whichever is the lesser period) so

long as:

(a) defects have arisen solely from faulty materials

or workmanship;

(b) the damage does not arise from:

(i) improper adjustment, calibration or

operation by the buyer;

(ii) the use of accessories including

consumables, hardware, or software which

were not manufactured by or approved in

writing by the seller;

(iii) any contamination or leakages caused or

induced by the buyer;

(iv) any modifications of the goods which were

not authorised in writing by the seller;

(v) any misuse of the goods by the buyer or

anyone for whom the buyer has legal

responsibility (including a minor);

(vi) any use or operation of the goods outside

of the physical, electrical or environmental

specifications of the goods;

(vii) inadequate or incorrect site preparation;

and

(viii) inadequate or improper maintenance of the

goods.

(ix) fair wear and tear of the product in an

environment in respect of which the Seller

has informed the Buyer in catalogues or

other product literature that the period of

usefulness of the product is likely to be

shorter that twelve 12 months.

(c) the goods have not received maltreatment,

inattention or interference;

(d) accessories of any kind used by the buyer are

manufactured by or approved by the seller;

(e) the seals of any kind on the goods remain

unbroken; and

(f) the defective parts are promptly returned free of

cost to the seller.

13.2 The seller is not liable for and the buyer

releases the seller from any claims in respect of

faulty or defective design of any goods supplied

unless such design has been wholly prepared by

the seller and the responsibility for any claim

has been specifically accepted by the seller in

writing. In any event the seller’s liability under

this paragraph is limited strictly to the

replacement of defective parts in accordance

with para 13.1 of these conditions.

13.3 Except as provided in these conditions, all

express and implied warranties, guarantees and

conditions under statute or general law as to

merchantability, description, quality, suitability

or fitness of the goods for any purpose or as to

design, assembly, installation, materials or

workmanship or otherwise are expressly

excluded. The seller is not liable for physical or

financial injury, loss or damage or for

consequential loss or damage of any kind

arising out of the supply, layout, assembly,

installation or operation of the goods or arising

out of the seller’s negligence or in any way

whatsoever.

14. Seller's liability

14.1 The seller's liability for a breach of a condition

or warranty implied by Div 2 of Pt V of the

Trade Practices Act 1974 (other than s 69) is

limited to:

(a) in the case of goods, any one or more of the

following:

(i) the replacement of the goods or the supply

of equivalent goods;

(ii) the repair of the goods;

(iii) the payment of the cost of replacing the

goods or of acquiring equivalent goods;

(iv) the payment of the cost of having the

goods repaired; or

(b) in the case of services:

(i) the supplying of the services again; or

(ii) the payment of the cost of having the

services supplied again.

Novatech Controls Pty. Ltd. ABN 57 006 331 700 Conditions of Sale

14.2 The seller's liability under s 74H of the Trade

Practices Act 1975 is expressly limited to a

liability to pay to the purchaser an amount equal

to:

(a) the cost of replacing the goods;

(b) the cost of obtaining equivalent goods; or

(c) the cost of having the goods repaired,

whichever is the lowest amount.

15. Prices

(a) Unless otherwise stated all prices quoted by

vendor are net, exclusive of Goods and Services

Tax (GST) and the buyer agrees to pay to the

seller any GST in addition to the price.

(b) Prices quoted are those ruling at the date of

issue of quotation and are based on rates of

freight, insurance, customs duties, exchange,

shipping expenses, sorting and stacking charges,

cartage, the quotation, cost of materials, wages

and other charges affecting the cost of

production ruling on the date is made.

(c) If the seller makes any alterations to the price of

the goods or to any of their inputs either before

acceptance of or during the currency of the

contract, these alterations are for the buyer’s

account.

16. Payment The purchase price in relation to goods is payable net

and payment of the price of the goods must be made

on or before the thirtieth day from the date of invoice

unless other terms of payment are expressly stated in

these conditions in writing.

17. Rights in relation to goods (Romalpa clause) The seller reserves the following rights in relation to

the goods until all accounts owed by the buyer to the

seller are fully paid:

(a) ownership of the goods;

(b) to enter the buyer's premises (or the premises of

any associated company or agent where the

goods are located) without liability for trespass

or any resulting damage and retake possession

of the goods; and

(c) to keep or resell the goods including any goods

repossessed pursuant to 17(b) above;

If the goods are resold, or goods manufactured using

the goods are sold, by the buyer, the buyer shall hold

such part of the proceeds of any such sale as

represents the invoice price of the goods sold or used

in the manufacture of the goods sold in a separate

identifiable account as the beneficial property of the

seller and shall pay such amount to the seller upon

request. Notwithstanding the provisions above the

seller shall be entitled to maintain an action against

the buyer for the purchase price and the risk of the

goods shall pass to the buyer upon delivery.

18. Buyer's property Any property of the buyer under the seller’s

possession, custody or control is completely at the

buyer’s risk as regards loss or damage caused to the

property or by it.

19. Storage The seller reserves the right to make a reasonable

charge for storage if delivery instructions are not

provided by the buyer within fourteen days of a

request by the seller for such instructions. The parties

agree that the seller may charge for storage from the

first day after the seller requests the buyer to provide

delivery instructions.

20. Returned goods

(a) The seller will not be under any duty to accept

goods returned by the buyer and will do so only

on terms to be agreed in writing in each

individual case.

(b) If the seller agrees to accept returned goods

from the buyer under para (a) of this clause, the

buyer must return the goods to the seller at the

seller’s place of business referred to at the head

of these conditions.

21. Goods sold All goods to be supplied by the seller to the buyer are

as described on the purchase order agreed by the

seller and the buyer and the description on such

purchase order modified as so agreed prevails over

all other descriptions including any specification or

enquiry of the buyer.

22. Cancellation No order may be cancelled except with consent in

writing and on terms which will indemnify the seller

against all losses.

23. Indemnity The buyer indemnifies on a continuing basis on a

fully indemnity basis the seller from and against any

liability, loss, expense or demand for or arising from

any false, misleading, deceptive or misdescriptive

representation or statement made by the buyer in

respect of the goods to any person. This indemnity

survives termination of this agreement by either part

for any reason.

24. Exclusion of representations and

arrangements Except as referred to in Clause 13.1herein, these

terms and conditions supersede and exclude all prior

and other discussions, representations (contractual or

otherwise) and arrangements relating to the supply of

the goods or any part of the goods including, but

without limiting the generality of the foregoing, those

relating to the performance of the goods or any part

of the goods or the results that ought to be expected

from using the goods.

25. No waiver The failure of any part to enforce the provisions of

this agreement or to exercise any rights expressed in

this agreement is not to be a waiver of such

provisions or rights an does not affect the

enforcement of this agreement.

26. Force Majeure If by reason of any fact, circumstance, matter or thing

beyond the reasonable control of the seller, the seller

is unable to perform in whole or in part any

obligation under this agreement the seller is relieved

of that obligation under this agreement to the extent

and for the period that it is so unable to perform and

is not liable to the buyer in respect of such inability.

27. Buyer Acknowledgement The Buyer acknowledges that the above provisions of

these Conditions of Sale are reasonable and reflected

in the price and the Buyer accepts the risks of the

Buyer associated with these Conditions of sale and/or

shall issue accordingly.

28. Place of contract

(a) The contract for sale of the goods is made in the

state of Victoria Australia.

(b) The parties submit all disputes arising between

them to the courts of such state and any court

competent to hear appeals from those courts of

first instance.

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